Multi-Port EV Battery Charging Control for Faster Safe DC Charging
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Solution Overview
Problem
Charging high voltage battery sources in medium to heavy duty electric vehicles is time-consuming due to the amount of charging required and limitations on charging rates to prevent overheating.
Innovation Solution
A system and method that detects the state of charge of multiple battery subpacks, selects the subpack with the higher charge for charging, and switches between constant current and constant voltage charging modes based on cell voltage thresholds, while providing power to accessory loads and pre-charging other subpacks to optimize charging efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If charging is performed at high rates to reduce charging time, then charging speed is improved, but overheating risk increases
Solution Approach 1:
The battery system is divided into multiple battery subpacks that can be charged independently through separate charge ports. This segmentation allows parallel charging of individual subpacks, increasing overall charging speed while maintaining safe charging rates for each subpack to prevent overheating.
Solution Approach 2:
The system detects state of charge levels of multiple battery subpacks and selects the subpack with lower charge for priority charging. This preliminary selection and pre-charging strategy optimizes charging efficiency by proactively managing which subpacks receive power first, reducing total charging time while preventing any single subpack from overheating.
2Productivity
If multiple battery subpacks are charged simultaneously through parallel charge ports, then charging time is reduced, but system complexity increases
Solution Approach 1:
Multiple charge ports are provided in the charging system, each capable of independently charging a battery subpack. These charge ports can function independently or in parallel, providing multi-functionality that reduces charging time while managing system complexity through standardized port designs and control logic.
3Productivity
If the charging system monitors and manages multiple battery subpacks, then charging efficiency is improved, but control complexity increases
Solution Approach 1:
The charging system continuously monitors the state of charge of multiple battery subpacks and uses this feedback to dynamically select which subpack to charge next or in parallel. This feedback mechanism optimizes charging efficiency by intelligently managing power distribution while the control logic handles the complexity of coordinating multiple subpacks.
Solution Approach 2:
The battery subpacks are equipped with individual state of charge detection capabilities, allowing them to self-report their charging status to the control system. This self-service approach reduces the burden on the central control system, improving charging efficiency while managing control complexity through distributed intelligence.
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
Reduces charging time by prioritizing the subpack with the lower state of charge and efficiently managing charging modes to prevent overheating, allowing for faster and safer battery charging.
Implementation Method 1
a first battery subpack, a second battery subpack... providing power from the selected battery subpack to an accessory load
Implementation Method 2
charging the selected battery subpack in a constant current charging mode until a cell voltage of a battery cell of the selected battery subpack reaches a voltage threshold and charging the selected battery subpack using a constant voltage charging mode
Data Source
AI summary
An electric vehicle, system and method of charging the electric vehicle. In another exemplary embodiment, a system for charging an electric vehicle is disclosed. The system includes a first battery subpack, a second battery subpack, and a processor. The processor is configured to determine a selected battery subpack from the first battery subpack and the second battery subpack for charging based on a comparison of a first state of charge of the first battery subpack a second state of charge of the second battery subpack and connect the selected battery subpack to a corresponding one of a first charge port and a second charge port.