Modular EV Chassis for Second-Life Battery Reconfiguration
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Solution Overview
Problem
The challenge lies in the high cost and inefficiency of repurposing high-voltage battery packs from retired electric vehicles for second-life applications, such as stationary energy storage, due to complications and declining new battery pack prices, making recycling or disposal more viable than reusing the batteries.
Innovation Solution
A reconfigurable electric drivetrain system for electric vehicles that includes a modular chassis with a high-voltage battery management system, allowing for the connection of multiple modules to form larger energy storage systems, enabling flexible use as both a drivable EV and a stationary energy storage unit, with sophisticated battery management algorithms to estimate the state of health and value of the batteries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If high-voltage battery packs from retired EVs are repurposed for second-life applications, then the value and utility of the batteries are extended, but the cost and complexity of repurposing are excessively high
Solution Approach 1:
The battery pack is divided into modular segments with standardized interfaces. Each module can be independently connected or disconnected, allowing flexible reconfiguration for different applications without requiring complete disassembly and reassembly of the entire battery system.
Solution Approach 2:
The battery pack is designed with universal power ports and communication ports that can interface with multiple different systems (EVs, stationary energy storage, grid). The standardized M2M ports enable the same battery hardware to serve multiple functions across different applications, reducing repurposing complexity.
2Quantity of substance
If multiple EV chassis modules are connected to form larger energy storage systems, then the energy storage capacity is increased, but the electrical connection complexity increases
Solution Approach 1:
The energy storage system is segmented into standardized chassis modules that can be connected in series or parallel configurations. Each module has defined electrical interfaces that simplify the connection process, allowing capacity scaling without proportionally increasing connection complexity.
Solution Approach 2:
Multiple chassis modules are merged into a unified energy storage system through standardized power ports. The modules combine their energy storage capacity while maintaining individual control through the communication network, achieving scalable capacity without linearly increasing system complexity.
3Reliability
If the battery management system controls electrical energy transfer between connected power ports, then the safety and efficiency are improved, but the system complexity increases
Solution Approach 1:
The battery management system continuously monitors the state of charge, voltage, and current of each connected module through communication ports. This feedback enables real-time control of electrical energy transfer, ensuring safety and efficiency while managing complexity through automated monitoring and control algorithms.
Solution Approach 2:
The battery management system provides universal control functions that work across different configurations of connected modules. The same control logic manages energy transfer whether modules are connected in series, parallel, or mixed configurations, reducing the need for configuration-specific control complexity.
4Ease of operation
If standardized power ports and communication ports are implemented on EV chassis, then the ease of connection and reconfiguration is improved, but the manufacturing complexity increases
Solution Approach 1:
The chassis is designed with standardized power ports and communication ports as separate, pre-fabricated components. These standardized interfaces can be manufactured independently and then integrated into the chassis assembly, distributing manufacturing complexity across modular components rather than requiring complex custom integration.
Data Source
AI summary
An electric vehicle (EV) chassis is disclosed that may be a modular platform flexible as a basis for numerous other EV platforms. It is contemplated that the entire electric drivetrain (i.e., powertrain, wheels, steering) may be supplied to an automotive original equipment manufacturer (OEM). The OEM may use the EV chassis for integration within a representative passenger compartment. The chassis may also be reconfigurable with the modularity at various levels that include the energy storage system, the entire chassis system, or any level in-between. The chassis may further be designed to allow connection of multiple modules to enable a larger scale energy storage that may be provided to homes, buildings, or the electric power grid.