Traction Battery Module Segmentation for Reliability
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Solution Overview
Problem
Current battery systems in traction applications, such as electric vehicles and wind power stations, face high failure rates due to individual cell failures, leading to system failures or safety issues, as the failure rate of a series circuit battery is significantly higher than that of individual cells, making it challenging to meet stringent reliability requirements.
Innovation Solution
The integration of disconnecting, charging, and bridging devices within battery modules allows for the bypassing of failed cells, maintaining system functionality with reduced power and preventing safety-critical states, while detecting failures and enabling repair procedures, thus enhancing system reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If individual battery cells are connected in series to achieve required performance and energy data, then the power and energy output of the battery system is improved, but the failure rate of the battery system increases significantly
Solution Approach 1:
The battery system is divided into multiple independent battery modules, each with its own disconnecting device. This segmentation allows individual modules to be isolated and bypassed without affecting the entire battery system, thereby maintaining power output while reducing the impact of cell failures on overall reliability.
Solution Approach 2:
Disconnecting devices are introduced as intermediary components between battery modules. These devices act as mediators that can open circuits to isolate failed modules, preventing failure propagation and enabling the battery system to maintain operational power while improving reliability through selective module disconnection.
2Reliability
If disconnecting devices are added to battery modules to isolate failed cells, then the reliability of the battery system is improved, but the device complexity increases
Solution Approach 1:
The battery system is segmented into modular units, each with integrated disconnecting devices. This modular segmentation distributes the complexity across independent units rather than requiring a complex centralized control system, making the overall system more manageable while improving reliability through localized failure isolation.
Solution Approach 2:
Each battery module is equipped with its own disconnecting device that can autonomously isolate failed cells within that module. This self-service capability eliminates the need for complex external monitoring and control systems, reducing overall device complexity while maintaining high reliability through automatic failure containment.
3Productivity
If bridging devices are implemented to bypass failed modules, then the availability of the battery system is maintained, but the manufacturing complexity increases
Solution Approach 1:
The battery system is organized into discrete, independently manufacturable modules with integrated bridging capabilities. This segmentation allows each module to be manufactured separately using standardized processes, reducing overall manufacturing complexity while enabling rapid assembly and maintenance that preserves system availability.
Solution Approach 2:
Battery modules are designed with universal interfaces and standardized disconnecting/bridging mechanisms that can be applied across all modules. This universality simplifies manufacturing by allowing the same components and procedures to be used throughout the system, while maintaining high availability through interchangeable module replacement.
Data Source
AI summary
The invention relates to a traction battery having at least two serially connected battery modules, each of which has a first battery module pole, a second battery module pole, and at least one inserted series circuit and/or parallel circuit of battery cells. A first terminal of the series circuit of battery modules is connected to a first battery pole, while a second terminal of the series circuit of battery modules is connected to a second battery pole. According to the invention, at least one battery module of the at least two serially connected battery modules is a first battery module which has at least one disconnecting device and a bridging device. When triggered accordingly, the at least one disconnecting device interrupts the connection between the series circuit and/or parallel circuit of battery cells and the first battery module pole and/or the second battery module pole and/or interrupts the series circuit and/or parallel circuit of battery cells. Furthermore, the first battery module pole and the second battery module pole are short-circuited via the bridging device inserted between the first battery module pole and the second battery module pole when the bridging device is triggered accordingly. Additionally or alternatively, at least one battery module of the at least two serially connected battery modules is a second battery module that has at least one charging and disconnecting device and a bridging device. When triggered accordingly, the at least one charging and disconnecting device interrupts the connection between the series circuit and/or parallel circuit of battery cells and the first battery module pole and/or the second battery module pole and/or interrupts the series circuit and/or parallel circuit of battery cells and limits charging or compensating currents occurring when the battery module or the battery comprising the battery module is connected. Furthermore, the first battery module pole and the second battery module pole are short-circuited via the bridging device inserted between the first battery module pole and the second battery module pole when the bridging device is triggered accordingly.