Parallel Battery Contactor Paths for On-the-Fly Verification
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Solution Overview
Problem
Traditional battery systems with single contactors cannot verify operation during vehicle use, especially at high current levels, and lack on-the-fly reconfiguration capabilities to ensure continuous operation in case of contactor failure.
Innovation Solution
A battery control system with multiple parallel contactor paths, each equipped with voltage and current sensors, and a controller that tests and reconfigures the contactors during vehicle operation to ensure continued functionality and extend contactor lifespan.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional single contactor systems are used, then the system structure is simple, but the system cannot verify contactor operation during vehicle use and cannot ensure continuous operation in case of contactor failure
Solution Approach 1:
The patent divides the single contactor system into multiple parallel contactor paths (first contactor path with first contactor, second contactor path with second contactor). This segmentation allows the system to verify operation of individual contactors during vehicle use and switch between paths if one contactor fails, thereby improving reliability without requiring complete system redesign
Solution Approach 2:
The controller is configured to test each contactor path during vehicle operation by selectively opening one contactor while the other remains closed, sensing voltages and currents to determine operational state. This preliminary testing capability allows the system to verify contactor functionality in advance before failures occur, enabling proactive reconfiguration
2Reliability
If contactor testing is performed during vehicle operation, then contactor failures can be detected, but power loss may occur during testing
Solution Approach 1:
The controller performs preliminary testing by selectively opening one contactor while the other contactor in the parallel path remains closed. This preliminary action ensures that if the tested contactor fails, the system has already prepared an alternative path, allowing failure detection without causing power loss
Solution Approach 2:
The parallel contactor paths provide beforehand cushioning by having a backup contactor path ready. When testing one contactor, the other contactor path serves as a cushion or safety net, ensuring continuous power supply even if the tested contactor fails during operation
3Duration of action of stationary object
If multiple parallel contactor paths are used, then on-the-fly reconfiguration is enabled and contactor lifespan is extended, but the device complexity increases
Solution Approach 1:
The system segments the current load across multiple parallel contactor paths, distributing current and wear evenly among contactors. This segmentation extends contactor lifespan by preventing any single contactor from bearing the full operational stress, while the modular parallel structure keeps the complexity manageable
Solution Approach 2:
The controller dynamically reconfigures the contactor paths during vehicle operation based on real-time operational state sensing. This dynamic adaptation allows the system to optimize contactor usage and extend lifespan by switching between paths, while the reconfiguration capability is managed through automated control logic rather than complex manual systems
Data Source
AI summary
A battery control system includes T contactor paths connected in parallel between a battery and a load, where T is an integer greater than one. Each of the T contactor paths includes a first contactor and a second contactor connected in series with the first contactor. Each of the T contactor paths includes at least one of a first voltage sensor configured to sense a first voltage between the first contactor and the second contactor; and a current sensor configured to sense current flowing through the first contactor and the second contactor. A second voltage sensor is configured to sense a second voltage at one end of the T contactor paths. A third voltage sensor is configured to sense a third voltage at an opposite end of the T contactor paths.