Swappable EV Battery Layout to Prevent DC Link Current Sloshing
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Solution Overview
Problem
Industrial machines face inefficiencies due to the need for extra 'pony' batteries, which increase weight, fuel consumption, and complexity, and pose challenges with wave reflection/current sloshing during battery replacement, particularly in machines with distributed power inverters.
Innovation Solution
Implementing a system with two swappable batteries, one providing power during normal operation and the other during replacement, eliminating the need for extra batteries and reducing current sloshing by dedicating each battery to a separate DC link and inverter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If extra smaller supplemental 'pony' batteries are carried to power machine systems during battery replacement, then machine run time is extended, but weight increases and fuel consumption increases
Solution Approach 1:
The battery system is segmented into multiple swappable battery packs, each capable of independent operation. This allows the machine to carry multiple smaller battery packs that can be quickly exchanged, extending operational duration without requiring a single large heavy battery or supplemental pony batteries.
Solution Approach 2:
Battery packs are pre-charged and prepared in advance, allowing hot swapping during operation. The system includes pre-positioned battery packs ready for immediate installation, eliminating the need to carry and manage supplemental pony batteries during field operations.
2Duration of action of moving object
If extra smaller supplemental 'pony' batteries are carried to power machine systems during battery replacement, then machine run time is extended, but device complexity increases
Solution Approach 1:
The battery system is divided into modular swappable packs with standardized interfaces. Each pack contains integrated management systems, simplifying the overall architecture compared to managing multiple different types of supplemental batteries with varying connection requirements.
Solution Approach 2:
The swappable battery packs are designed as universal units that can serve multiple functions: primary power source, backup power, and hot-swappable replacement units. This multi-functionality eliminates the need for separate pony batteries and reduces system complexity.
3Duration of action of moving object
If pony batteries are used during battery replacement, then machine run time is extended, but current sloshing and wave reflection occur on the DC link
Solution Approach 1:
The battery management system performs preliminary assessment of battery state, charge levels, and system load before initiating a swap. This pre-planning allows for coordinated switching that maintains DC link stability and prevents current sloshing by ensuring seamless power transition.
Solution Approach 2:
The control system acts as an intermediary between the battery packs and the DC link, managing the switching process to prevent electrical transients. The controller coordinates the disconnection and connection sequences, using intermediate circuit elements to dampen potential current sloshing and wave reflection.
4Device complexity
If traditional battery replacement is used, then system simplicity is maintained, but wait time for recharging increases and production efficiency decreases
Solution Approach 1:
Battery packs are pre-charged and prepared in advance at charging stations, allowing them to be ready for immediate installation. This preliminary preparation eliminates waiting time during field operations while maintaining simple swap procedures that do not require complex replacement systems.
Solution Approach 2:
The system includes automated battery management and tracking that handles charging schedules and swap coordination without requiring complex manual intervention. This self-service capability reduces wait times while keeping the overall system simple and easy to operate.
Data Source
AI summary
The electric vehicle that may comprise an electrical power system that includes a first DC link; a first swappable battery in electrical communication with the first DC link, and a second swappable battery substantially the same as the first swappable battery. The first swappable battery is configured to provide power to the electric vehicle during normal operation of the electric vehicle and to at least a first operation of the electric vehicle while the second swappable battery is removed from the electric vehicle and replaced. The second swappable battery is substantially the same as the first swappable battery and disposed on the electric vehicle, the second swappable battery configured to provide power to the electric vehicle during normal operation of the electric vehicle and to at least a second operation of the electrical vehicle while the first swappable battery is removed from the electric vehicle.