Vehicle Battery Pack Reconfiguration for High-Power Multi-Voltage Operation
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Solution Overview
Problem
Existing electric and hybrid vehicles with multiple battery packs connected in parallel face limitations in providing both high power and efficient operation, especially when some loads require lower voltage.
Innovation Solution
A system that dynamically switches between series and parallel connections of battery packs, allowing certain loads to receive power directly from a subset of batteries independently of the connection mode, and includes a controller to manage switches and ensure efficient power distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If battery packs are connected in parallel for vehicle operation, then the system provides stable power for low voltage loads, but the vehicle cannot operate at higher power modes
Solution Approach 1:
The patent implements dynamic switching between series and parallel battery pack connections based on vehicle operational requirements. A controller monitors vehicle conditions and activates appropriate operational modes: series connection for high power modes and parallel connection for normal operation with low voltage loads. This dynamic reconfiguration allows the system to adapt its voltage output (480V series or 240V parallel) to match real-time power demands.
Solution Approach 2:
The system changes the electrical parameters of the battery pack configuration by switching between series and parallel connections. This parameter change transforms the system from a fixed parallel configuration to a variable configuration that can output different voltages (240V or 480V) and currents, thereby enabling both high power operation and compatibility with low voltage loads through controlled parameter modification.
2Power
If battery packs are reconfigured for high power modes, then the vehicle gains higher power output, but low voltage loads cannot receive constant power
Solution Approach 1:
The patent segments the battery pack system into two independent power delivery paths: one for high voltage propulsion motors and another for low voltage auxiliary loads. By creating separate connection pathways, the system can configure battery packs in series for high power motor operation while simultaneously maintaining parallel connections for low voltage load power supply, thus isolating the two functions from each other's configuration changes.
Solution Approach 2:
The battery pack system is designed with multi-functionality to serve dual purposes: it can deliver high power for propulsion motors through series connection while simultaneously providing stable power to low voltage auxiliary loads through parallel connection. This universal design allows the same battery packs to fulfill multiple functional requirements without compromising either high power output or low voltage load reliability.
3Adaptability or versatility
If DC-DC converters are used to power low voltage loads during series operation, then all loads can be powered, but system complexity and weight increase
Solution Approach 1:
The patent extracts the DC-DC conversion function from the overall system by providing direct parallel connection pathways for low voltage loads. Instead of relying on electronic converters to step down voltage, the system physically connects low voltage loads directly to battery packs configured in parallel, thereby eliminating the need for DC-DC converters and their associated weight, complexity, and potential failure points.
Solution Approach 2:
The patent introduces configurable switches as intermediaries between the battery packs and low voltage loads. These switches act as simple mechanical or electronic mediators that can be opened or closed to establish or disconnect parallel connections, providing a lightweight alternative to complex DC-DC converter systems while maintaining the ability to deliver appropriate voltage to low voltage loads.
Data Source
AI summary
A vehicle includes two or more battery packs configured to power a motor. A controller is configured to dynamically activate an operational mode during operation. The operational mode is one of multiple possible operational modes including a first operational mode defining a series connection between the two or more battery packs and second operational mode defining a parallel connection between the two or more battery packs. The connection between the battery packs is controlled by a first plurality of switches. A plurality of low voltage loads are connected to a subset of the battery packs in the battery packs such that a power output of the subset of the battery packs provides full power to the plurality of low voltage loads. The plurality of low voltage loads are connected to only the subset of the battery packs in both the first operational mode and the second operational mode.