Vehicle Power Supply Bypass Layout for Battery Fault Isolation
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Solution Overview
Problem
Current vehicle power supply systems for electric and hybrid-electric vehicles face challenges in achieving improved power supply reliability while maintaining low overall vehicle cost-efficiency and weight, particularly in providing redundant high-voltage and low-voltage power.
Innovation Solution
A power supply system comprising two series-connected high-voltage battery units with bypass lines and circuit breakers, DC/DC converters, and main contactors, allowing for isolation of faulty units and maintaining power supply through redundant pathways, thereby reducing weight and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If redundant power supply components are added to improve reliability, then power supply reliability is improved, but vehicle weight and cost increase
Solution Approach 1:
The patent combines the functions of multiple DC/DC converters into a single unit that can provide redundant low-voltage power supply. The converter is designed with internal redundancy mechanisms, merging what would traditionally be separate redundant components into one integrated unit, thereby maintaining reliability while reducing overall weight and cost.
Solution Approach 2:
The DC/DC converter is designed with multi-functional capability, where a single converter can serve multiple purposes: normal power conversion, standby redundancy, and fault isolation. The converter can operate in different modes (normal operation, degraded mode with one battery unit disconnected) and can support multiple output pathways, eliminating the need for dedicated redundant converter components.
2Reliability
If redundant power supply components are added to improve reliability, then power supply reliability is improved, but vehicle cost increases
Solution Approach 1:
The patent merges redundant power supply functions into a single DC/DC converter unit, reducing the total component count and assembly complexity. This integration approach lowers manufacturing costs by eliminating the need for multiple separate converter units, connectors, and control systems that would be required for traditional redundant architectures.
Solution Approach 2:
The converter design utilizes parameter changes and configurable operation modes to achieve redundancy without additional hardware. By changing operational parameters and control logic, the single converter can provide redundant power supply capability, avoiding the cost of duplicate hardware components.
3Adaptability or versatility
If bypass lines and circuit breakers are added to isolate faulty units, then fault isolation capability is improved, but device complexity increases
Solution Approach 1:
The patent integrates bypass functionality and circuit protection directly into the DC/DC converter unit, combining what would traditionally be separate external components (bypass lines, circuit breakers, isolation switches) into the converter's internal architecture. This integration maintains fault isolation capability while reducing overall system complexity and component count.
Solution Approach 2:
The DC/DC converter acts as an intermediary device that mediates between the high-voltage battery units and the low-voltage load. It incorporates internal isolation mechanisms and control logic that automatically manage fault isolation, eliminating the need for external bypass lines and circuit breakers while maintaining the same protective functionality.
4Weight of moving object
If series connection of battery units is used to reduce weight, then vehicle weight is reduced, but vulnerability to single-point failures increases
Solution Approach 1:
The patent implements beforehand cushioning by designing the DC/DC converter with pre-integrated redundancy capabilities and automatic fault response mechanisms. The converter is prepared in advance to handle battery unit failures through internal bypass paths and control logic that automatically activate upon detecting faults, cushioning the system against the vulnerabilities inherent in series connection without requiring additional weight.
Solution Approach 2:
The converter incorporates feedback mechanisms that continuously monitor the status of series-connected battery units and automatically adjust operation to maintain reliability. When a failure is detected in one battery unit, the feedback control system activates redundant pathways and isolates the faulty unit, ensuring continued reliable operation despite the series connection configuration.
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
The system ensures continued power supply with reduced weight and cost by isolating faulty units and maintaining low-voltage power delivery, even in the event of failures, while handling short-circuits and single faults effectively.
Implementation Method 1
a first DC/DC converter connected to the positive and negative power distribution arrangements and configured for providing a first low-voltage DC output
Data Source
AI summary
A vehicle power supply system provides redundant high-voltage and low-voltage power supply for an electric vehicle or a hybrid-electric vehicle. The power supply system includes first and second high-voltage battery units. A positive terminal of the first unit is connected to a positive power distribution arrangement and a positive terminal of the second unit is connected to a negative terminal of the first high-voltage battery unit via an intermediate power distribution arrangement, and a negative terminal of the second unit is connected to a negative power distribution arrangement. The system has a first bypass line connecting the positive power distribution arrangement with the intermediate power distribution arrangement, and a second bypass line connecting the negative power distribution arrangement with the intermediate power distribution arrangement.