Reconfigurable Multi-Pack Battery System for Adaptive Charging
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Solution Overview
Problem
The integration of higher-power DC fast-charging infrastructure with existing battery pack architectures is hindered by mismatched voltage ratings, necessitating a flexible charging and propulsion system that can adapt to various voltage levels and modes to optimize battery utilization and compatibility with both high-power and legacy charging stations.
Innovation Solution
A reconfigurable multi-pack battery system that connects battery packs in parallel for propulsion and series for charging, allowing voltage levels to be adjusted based on available charging voltage, with a controller managing switch states to select appropriate configurations for different operating modes, enabling flexible use of DC fast-charging stations and balancing battery pack states of charge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If battery packs are connected in series to increase voltage for DC fast-charging, then charging power and speed are improved, but compatibility with legacy charging infrastructure is lost
Solution Approach 1:
The battery pack system dynamically reconfigures its internal connection topology between series and parallel configurations based on the charging voltage detected from the external charging station. When high-voltage DC fast-charging is detected, packs connect in series to accept higher power; when legacy charging voltage is detected, packs reconfigure to parallel connection for compatibility, enabling adaptive response to different charging infrastructure types.
Solution Approach 2:
The system changes the electrical configuration parameter of the battery packs from fixed to variable, allowing the voltage rating and connection topology to be adjusted based on external charging conditions. This parameter change enables the same battery pack system to operate with both high-voltage DC fast-charging infrastructure and legacy charging stations.
2Adaptability or versatility
If battery packs are connected in parallel for propulsion operations, then voltage compatibility with legacy systems is maintained, but charging power capability is limited
Solution Approach 1:
The battery pack system dynamically switches between parallel connection during propulsion operations for legacy system compatibility and series connection during DC fast-charging operations for enhanced power capability. This dynamic reconfiguration allows the system to optimize for the appropriate function based on operational mode.
Solution Approach 2:
The battery pack system is designed to perform multiple functions through reconfigurable connections: it can operate in parallel configuration for both propulsion and legacy charging, then switch to series configuration for DC fast-charging, making the system universal across different operating conditions and infrastructure types.
3Device complexity
If fixed voltage rating battery packs are used, then system design is simplified, but flexibility in utilizing different charging voltages is reduced
Solution Approach 1:
Instead of using battery packs with fixed voltage ratings, the system employs dynamically reconfigurable battery packs that can change their effective voltage rating by altering internal connection topology. This dynamic approach provides voltage flexibility without requiring multiple different battery pack designs.
Solution Approach 2:
The battery system is segmented into multiple independently controllable battery packs, each capable of being reconfigured between series and parallel connections. This segmentation allows flexible voltage composition while maintaining manageable individual pack designs.
Data Source
AI summary
A multi-pack battery system having at least first and second battery packs each with positive and negative terminals, and each with upper and lower switches respectively connected to the positive and negative terminals. The battery packs have a first voltage level, and are connectable in either series or parallel. A controller controls an ON/OFF state of the switches in response to input signals to select between two series charging modes, three parallel charging modes, and one or more propulsion modes. Some embodiments have a series propulsion mode. An electric powertrain system includes first and second power inverter modules (“PIMs”), an electrical load, front and rear electric machines connected to a respective one of the first and second PIMs, and the battery system. The powertrain system may selectively provide all-wheel, front-wheel, or rear-wheel drive capabilities in each of the various propulsion modes.