All-Electric Range Extender Topology for Battery Electric Vehicles
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Solution Overview
Problem
The limited range of electric vehicles due to high costs and weight associated with larger batteries, and the difficulty in adding additional battery capacity post-production, which increases range anxiety for consumers.
Innovation Solution
A power distribution system that allows for the temporary connection of an external battery or energy storage module, known as the All-Electric Range Extender Solution (AERES), which can operate as a power source to provide power to the high-voltage bus during vehicle operation and charge the traction battery when not in use, integrated with minimal changes to the existing vehicle power distribution system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If a larger battery is permanently installed to address range anxiety, then the vehicle range is improved, but the cost and weight of the vehicle increase
Solution Approach 1:
The battery system is segmented into two independent parts: a permanent traction battery installed in the vehicle and a removable external battery that can be attached or detached. This segmentation allows the vehicle to have extended range capability without permanently carrying the additional weight, as the external battery can be removed when not needed for long trips
Solution Approach 2:
The battery configuration is made dynamic and adjustable rather than fixed. The vehicle can adapt its battery capacity by connecting or disconnecting the external battery based on trip requirements. The power management system dynamically switches between operating modes (traction battery only, external battery only, or both together) to optimize range and weight
2Duration of action of moving object
If a larger battery is permanently installed to address range anxiety, then the vehicle range is improved, but the cost of the vehicle increases
Solution Approach 1:
The battery system is segmented into two independent parts: a permanent traction battery installed in the vehicle and a removable external battery that can be attached or detached. This segmentation allows the vehicle to have extended range capability without permanently carrying the additional weight, as the external battery can be removed when not needed for long trips
Solution Approach 2:
The external battery serves multiple functions: it can be used alone for short trips, combined with the traction battery for extended range, or removed entirely to reduce weight and cost for everyday use. The power management system supports multiple operating modes including charging the external battery from the traction battery or from external charging sources, providing versatile functionality
3Duration of action of moving object
If additional battery capacity is added post-production, then the vehicle range is improved, but the complexity of the power distribution system increases
Solution Approach 1:
The existing power distribution components (power converter, contactors, control circuits) are designed to perform multiple functions: managing power flow between the charge port and traction battery, managing power flow between the external battery and traction battery, and coordinating charging operations. This multi-functionality reduces the need for separate dedicated components for each function
Solution Approach 2:
The power converter serves as an intermediary device that mediates power transfer between different battery systems and the charge port. It provides voltage conversion and isolation, allowing the external battery (which may have different voltage characteristics) to be integrated with the vehicle's existing electrical architecture without requiring extensive modifications to the power distribution system
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
Enables the extension of vehicle range without increasing the vehicle's cost or weight, allowing owners to add battery capacity as needed, such as for long trips, while ensuring safe and efficient power management through a controller that operates in various modes to optimize energy transfer between the traction battery, external battery, and high-voltage bus.
Implementation Method 1
a first set of switching devices configured to selectively transfer power between a charge port and the first bus. The power converter further includes a second set of switching devices configured to selectively transfer power between the first bus and a second bus that is coupled to the traction battery
Implementation Method 2
operate the second set to cause a second nominal voltage, different than the first nominal voltage, on the first bus in a second operating mode to transfer power from the connection interface to the traction battery
Data Source
AI summary
A power converter for an electric vehicle include a connection interface for coupling an external battery to a first bus. The power converter includes a first set of switching devices configured to transfer power between a charge port and the first bus, and a second set of switching devices configured to transfer power between the first bus and a second bus coupled to a traction battery. The power converter includes a controller programmed to control a voltage level of the first bus to different nominal operating voltages based in different operating modes.