Range Extension System Direct High Voltage Bus Connection
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Solution Overview
Problem
Existing portable recharging systems for electric and hybrid vehicles are inefficient due to energy loss and slow charging processes, requiring conversion between direct and alternating current, and do not allow immediate vehicle use after connection.
Innovation Solution
A range extension system with electrical connections to the vehicle's high voltage bus and onboard battery disconnection mechanisms, enabling direct energy use from range extension batteries without conversion, promoting energy efficiency and immediate vehicle use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If portable recharging systems use vehicle charging plug and converter between direct and alternating voltage, then recharging capability is provided, but energy transfer efficiency is reduced and recharging speed is slow
Solution Approach 1:
The patent extracts and eliminates the converter between direct and alternating voltage from the recharging system. By directly connecting the portable recharging module to the vehicle's high voltage bus through a high voltage connector, the system bypasses the inefficient AC-DC conversion process, thereby reducing energy transfer loss and enabling faster recharging.
Solution Approach 2:
The patent discards the conventional charging plug and converter components that cause energy loss. Instead, it recovers and utilizes the vehicle's existing high voltage bus and high voltage connector system, which are already optimized for efficient direct current transmission, thereby achieving rapid and efficient recharging.
2Reliability
If range extension module connects through alternate voltage connection with converter and charger, then recharging is enabled, but electrical cable length increases causing energy losses and delays
Solution Approach 1:
The patent removes the converter and charger components from the connection path between the portable recharging module and the vehicle. By directly connecting to the high voltage bus, the system eliminates the need for long electrical cables and intermediate conversion devices, thereby reducing energy loss and connection delays while maintaining reliable vehicle operation.
3Productivity
If conventional recharging systems are used, then vehicle can be recharged, but instantaneous use of vehicle is not possible after connection
Solution Approach 1:
The patent implements preliminary action by directly connecting the portable recharging module to the vehicle's high voltage bus before power transfer begins. This direct connection setup eliminates the time required for voltage conversion and system initialization, allowing instantaneous power transfer and immediate vehicle availability upon connection.
Data Source
Figure 1~2
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AI summary
The system comprises, preferably, an external range extension subsystem (1) with a range extension battery (5), a high to low voltage converter (32), a pre-charge resistor (19), power contactors (16,17,18) connected to the first range extension control subsystem (6), a first electrical supply line for contactors (23) and a control connections (24,25,26); and an onboard range extension subsystem (2) with a power distribution module (100), power contactors (20,21,22) linked by an electrical supply line (27) and control connections (28,29,30) to a second range extension control subsystem (7) with a digital communications bus of the vehicle (31); connectable by high voltage connection (8,9,10,11) and electrical contact check connections (12,13), electrical connection elements (3,4) and digital communications bus (14,15). The system allows the immediate use of the electric energy available in the range extension batteries.