Plug-in Bussed Electrical Center for Hybrid Vehicle Energy Storage
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Solution Overview
Problem
Existing energy storage systems for hybrid electric vehicles face challenges such as overheating, weight, complexity, ease of incorporation, ease of service, and cost, particularly due to the need for specific battery packs designed for specific voltage requirements, and the reliance on separate control boxes that can lead to system failure if compromised.
Innovation Solution
The energy storage system comprises modular secondary battery arrays with a pack-to-pack CAN bus for communication, a master-slave configuration, a weather-resistant enclosure with a heat sink and fan for cooling, and a plug-in bussed electrical center for efficient energy distribution, eliminating the need for a separate control box and enhancing redundancy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate control boxes are used for battery management, then control functionality is provided, but system reliability decreases and device complexity increases
Solution Approach 1:
The patent integrates the control box functionality directly into the battery pack assembly, merging previously separate control functions with the battery management system. This integration eliminates the need for separate control boxes while maintaining all necessary control capabilities, thereby improving system reliability and reducing overall device complexity
Solution Approach 2:
The integrated control system performs multiple functions including battery monitoring, thermal management control, and communication within the hybrid vehicle system. By consolidating these functions into a single integrated unit rather than separate components, the system achieves multi-functionality that improves reliability while managing complexity
2Adaptability or versatility
If battery packs are designed for specific voltage requirements, then energy storage needs are met, but adaptability decreases and re-engineering is required
Solution Approach 1:
The battery system is divided into modular battery packs that can be independently configured. Each module contains standardized components that can be assembled in different configurations to achieve various voltage requirements, enabling adaptability without requiring complete re-engineering of the entire battery system
Solution Approach 2:
The patent employs a standardized module design where the same basic battery module can be configured for different voltage requirements by changing the series/parallel arrangement of modules. This parameter change approach allows the system to adapt to different voltage needs (e.g., 300V vs 600V systems) without requiring fundamental redesign of the battery packs
3Quantity of substance
If multiple separate battery packs are used, then energy storage capacity increases, but system complexity and weight increase
Solution Approach 1:
The battery system uses segmented modular units that can be stacked or connected to achieve desired capacity. Each module is a self-contained unit with standardized interfaces, allowing multiple modules to be combined for increased capacity while maintaining manageable system complexity through modular architecture
Solution Approach 2:
The patent implements a hierarchical modular structure where individual battery cells are grouped into modules, modules are grouped into packs, and packs can be grouped into complete battery systems. This nested arrangement allows capacity scaling while managing complexity at each hierarchical level through standardized interfaces and configurations
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
This solution improves the efficiency, reliability, and adaptability of energy storage in hybrid electric vehicles by allowing modular expansion, reducing weight and complexity, and ensuring system functionality even if individual modules fail, while minimizing the need for extensive re-engineering across different voltage applications.
Implementation Method 1
a heat sink disposed on an exterior surface of the primary enclosure, the heat sink comprising a plurality of substantially rigid fins constructed of a thermally conductive material
Implementation Method 2
a fan mounted to an exterior surface of the first end of the primary enclosure, wherein the fan is operable to direct air across the fins
Data Source
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AI summary
An energy storage system comprising at least one energy storage module adapted to supply electrical energy to a hybrid vehicle. The energy storage module comprises an enclosure, at least one battery array located within the enclosure, and an energy storage controller module located within the enclosure and electrically connected to the battery array. A plug-in bussed electrical center for use in the hybrid vehicle is provided, comprising: a modular removable connector formed of electrically insulative material having a plurality of connecting terminals; wherein the plurality of connecting terminals are configured to electrically connect a battery adapted to supply energy to the hybrid vehicle and a hybrid vehicle drive system; wherein the plurality of connecting terminals are electrically connected to the battery by pluggable connectors.