Modular Battery Pack Reconfiguration for 3P-to-2P Voltage Switching
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Solution Overview
Problem
Existing modular battery systems face challenges in achieving switchable configurations that can support a battery pack with a 3P100S configuration to switch to a higher voltage for charging, as traditional circuits with a 2:1 ratio are not capable of supporting such needs due to indivisible cell ratios, limiting component re-use, packaging, and voltage requirements.
Innovation Solution
A modular battery system with multiple interconnected battery modules and a controller that selectively positions switches to transition between a first configuration providing three parallel electrical pathways and a second configuration providing two parallel pathways, allowing the battery pack to switch between propulsion and charging modes, thereby enabling a 3:2 ratio and supporting higher voltage charging without re-designing motors or inverters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional circuits with 2:1 ratio are used, then component re-use and packaging are simplified, but the ability to support higher voltage charging is limited due to indivisible cell ratios
Solution Approach 1:
The battery pack is divided into multiple modular battery modules (first group, second group, third group, fourth group) that can be independently switched and reconfigured. This segmentation allows flexible arrangement of cells in series and parallel to achieve different voltage and current configurations, enabling both 400V propulsion mode and 600V charging mode without being constrained by fixed 2:1 ratios.
Solution Approach 2:
The patent implements dynamic reconfiguration of battery modules using switches that can change the circuit topology in real-time. The system transitions from a fixed configuration to a dynamic one where battery modules can be reorganized between series and parallel connections based on operational requirements (propulsion vs. charging), enabling adaptable voltage output.
2Adaptability or versatility
If battery modules are fixed in a single configuration, then device complexity is reduced, but the system cannot switch between propulsion and charging modes with different voltage requirements
Solution Approach 1:
The same battery module is designed to serve multiple functions by changing its electrical configuration. The battery pack can operate in propulsion mode (400V, three parallel pathways) or charging mode (600V, two parallel pathways) using the same physical cells, achieving multi-functionality without requiring separate battery systems for each mode.
Solution Approach 2:
The system employs dynamic switching mechanisms that reconfigure battery module connections based on operational mode. Switches enable real-time transition between series and parallel arrangements, allowing the battery pack to adapt its voltage and current characteristics to match either propulsion or charging requirements.
3Power
If higher voltage is applied for charging, then charging power is increased, but excessive voltage may damage propulsion components when in propulsion mode
Solution Approach 1:
The system dynamically adjusts voltage output by reconfiguring battery module connections. In charging mode, modules are arranged to provide 600V for high-power charging. In propulsion mode, the same modules are reconfigured to output 400V, preventing excessive voltage from damaging propulsion components while maintaining high power capability when needed.
Solution Approach 2:
The patent changes electrical parameters (voltage and current) by altering the series-parallel configuration of battery modules. By changing the number of cells in series versus parallel, the system adjusts output voltage to match operational requirements: 600V for charging, 400V for propulsion, thereby avoiding voltage-related damage while optimizing power delivery.
Data Source
AI summary
A modular battery system includes a battery pack with multiple battery modules electrically interconnected via a plurality of electrical cables. A plurality of switches selectively connects the multiple battery modules. A direct current (DC) charge connector is configured to electrically connect the battery pack to an off-board DC fast-charging station, via the plurality of electrical cables. The pack circuit is adapted to switch between a first configuration and a second configuration based on a respective position of the plurality of switches. A controller is configured to select the respective position of each of the plurality of switches to transition the pack circuit between the first configuration and the second configuration, in response to input signals indicative of a requested operating mode of the battery pack. The first configuration provides three parallel electrical pathways, and the second configuration provides two parallel electrical pathways.