Swappable EV Battery Charging Through an On-Board DC Converter
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Solution Overview
Problem
Electric vehicles face challenges with reduced travel distance range due to battery deterioration and long charging times, and the cost and complexity of establishing infrastructure for swappable batteries.
Innovation Solution
An electric vehicle system that includes a main battery unit and a swappable battery unit, where the main battery unit is charged through the swappable battery unit without the need for additional voltage boosting means, utilizing an on-board charger and a switch unit to manage power flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If the size (capacity) of the battery is increased to extend EV mileage, then the travel distance range is improved, but the vehicle weight and price are increased
Solution Approach 1:
The battery system is segmented into a main battery unit (fixedly disposed) and a swappable battery unit (detachably mounted). This allows the vehicle to achieve extended mileage through the swappable battery without permanently increasing the base vehicle weight, as the swappable battery can be removed when not in use.
Solution Approach 2:
The swappable battery unit can be detached and replaced with a fully charged unit when needed, effectively recovering the extended range capability without permanently carrying the additional weight. The system allows users to exchange depleted swappable batteries for charged ones at charging stations.
2Duration of action of moving object
If the size (capacity) of the battery is increased to extend EV mileage, then the travel distance range is improved, but the vehicle price is increased
Solution Approach 1:
By segmenting the battery into main and swappable units, the vehicle's base price remains lower while offering an optional path to extended mileage. Users only pay for the swappable battery unit when they need extended range, making the high-capacity capability available on-demand rather than requiring all users to purchase expensive large batteries.
Solution Approach 2:
The system allows dynamic change of battery capacity parameters through swapping. The vehicle can operate with a smaller main battery for daily use, and temporarily access larger combined capacity when the swappable unit is attached, enabling flexible mileage adjustment without permanent price increase.
3Loss of time
If a swappable battery infrastructure is established to solve charging time issues, then the charging speed is improved, but the infrastructure cost and complexity are increased
Solution Approach 1:
The system enables self-service battery replacement at charging stations, where users can autonomously detach depleted swappable batteries and attach charged ones without requiring complex automated handling infrastructure. This simplifies the charging station design compared to fully automated systems.
Solution Approach 2:
The swappable battery unit acts as an intermediary between the vehicle and the charging infrastructure. Instead of directly charging the vehicle's main battery through complex high-power charging equipment, the system uses simpler battery exchange operations, reducing the technical complexity required at charging stations.
4Adaptability or versatility
If additional voltage boosting means are added to charge the main battery from the swappable battery, then the power source flexibility is improved, but the device complexity and cost are increased
Solution Approach 1:
The on-board charger is designed to perform multiple functions: it can charge the main battery from external power sources and also function as a DC converter to accept power from the swappable battery unit. This multi-functionality eliminates the need for separate voltage boosting equipment, reducing system complexity while maintaining power source flexibility.
Solution Approach 2:
The patent merges the functions of external charging and swappable battery charging into a single on-board charger system. The switch unit integrates multiple connection paths, allowing the same hardware to handle different power sources without requiring additional dedicated equipment for each charging method.
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 allows for extended travel range by enabling efficient charging of the main battery from the swappable battery, while reducing the need for additional infrastructure and minimizing weight and cost increases associated with larger batteries.
Implementation Method 1
an on-board charger (OBC) connected between the main battery unit and the inverter, the OBC including a direct current (DC) converter
Data Source
AI summary
An electric vehicle may be equipped with a swappable battery, and a power source management method. The electric vehicle includes a motor, an inverter configured to exchange three-phase power with the motor, a main battery unit which may be electrically connected to the inverter, includes a first battery and a first BMS for controlling the first battery, and may be fixedly disposed in the electric vehicle, an OBC which may be connected between the main battery unit and the inverter and includes a DC converter, and a switch unit configured to selectively connect a connector and the DC converter to each other, or the connector and the motor to each other, in which, when a swappable battery unit including a second battery and a second BMS for controlling the second battery may be connected to the connector, the first BMS acquires second-battery information output by the second BMS.