Segmented Heterogeneous Battery System for Hybrid Vehicles
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Solution Overview
Problem
High power battery systems in electric and hybrid vehicles face limited life cycles and underutilized capacity due to uneven energy distribution and imbalance between different battery chemistries, leading to reduced performance and environmental impact when attempting to upgrade or modify existing systems.
Innovation Solution
Implementing a multiple stage heterogeneous battery system with a primary module handling transient loads and a secondary module managing constant loads, connected through a DC/DC Converter and Controller (DDCC) to optimize energy release and prevent overcharging/over-discharging, allowing for different nominal voltages and chemistries while maintaining battery health.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a new string of battery module is added directly to the stock battery module in parallel, then battery capacity is increased, but battery life is reduced due to imbalance issues from different chemistry and voltage levels
Solution Approach 1:
The battery system is segmented into two separate modules: a primary battery module (stock) and a secondary battery module (added). Each module operates independently with its own management, connected through a DC/DC converter. This segmentation allows each battery type to be optimized for its specific chemistry and voltage characteristics while working together to provide increased total capacity without the imbalance issues of direct parallel connection.
Solution Approach 2:
A DC/DC converter is introduced as an intermediary device between the primary and secondary battery modules. This mediator controls the energy transfer between the two different voltage levels and chemistry types, preventing direct interaction that would cause imbalance. The converter ensures proper charging/discharging sequences and protects each module from operating outside its optimal range, thereby preserving battery life while utilizing the combined capacity.
2Duration of action of stationary object
If the battery state of charge is maintained at 40% to 80% range, then design service life is extended, but 60% of battery capacity is not utilized during daily driving
Solution Approach 1:
The battery system is divided into primary and secondary modules with different functions. The primary module maintains the safe 40-80% SOC range for longevity, while the secondary module handles deep cycling operations. This segmentation allows the system to preserve the life-extending SOC strategy for the primary battery while utilizing the secondary battery's full capacity for energy storage and release during driving cycles.
Solution Approach 2:
The secondary battery module is designed to operate in deep cycling mode (0-100% SOC), performing the partial function of energy buffering that would otherwise require the primary module to operate outside its safe range. By having the secondary module take on this excessive action of deep discharge/charge cycles, the primary module can maintain its conservative SOC strategy for extended life while the system as a whole achieves high capacity utilization.
3Quantity of substance
If hybrid electric vehicle is converted to plug-in hybrid by adding battery module, then energy storage is increased, but original manufacturer components are impacted and emissions increase
Solution Approach 1:
The DC/DC converter serves as an intermediary that interfaces with the existing vehicle controller and powertrain components without requiring their modification. It translates between the different voltage levels and control protocols of the old and new battery systems, allowing the conversion to proceed while preserving the original manufacturer components and their control algorithms, thereby avoiding increased emissions from altered operation.
Solution Approach 2:
The secondary battery module and DC/DC converter combination is designed to be universally compatible with the existing hybrid vehicle platform. The system can operate in multiple modes: the secondary module can charge from regenerative braking, from external sources in plug-in mode, or from the primary module when needed. This multi-functionality allows increased energy storage while maintaining compatibility with original components and preserving their designed emission characteristics.
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 approach prolongs battery life and increases usable capacity by maintaining the primary module within a safe SOC range and fully utilizing the secondary module, reducing wear and tear, and enabling efficient energy transfer without altering original manufacturer components or increasing emissions.
Implementation Method 1
connected through a DC/DC Converter and Controller (DDCC) to optimize energy release and prevent overcharging/over-discharging
Data Source
AI summary
A multiple stage battery system has significantly improved battery life in hybrid and electric motorized vehicle. At least two segments of battery packs are charged and discharged with two different battery management strategies, one handles transient energy needs and the other copes with cruise energy needs. The primary segment of battery are charged and discharged within a controlled State of Charge (SOC) range at a set point, it stores relatively less energy but supplies relative high impulse current during charge and discharge. The secondary segments have larger energy capacity, and are charged and discharged at constant current mode in deep cycling, near complete full charge and full discharge. These two segments of batteries could be different type of chemistry, i.e. NiMH, NiCD and Li-ion. This results in longer overall battery life and higher usable capacity for high power battery operations.