DESC:VEHICLE (EV)
CROSS REFERENCE TO RELATED APPLICTIONS
The present application claims priority from Indian Provisional Patent Application No. 202221075289 filed on 25/12/2022, the entirety of which is incorporated herein by a reference.
TECHNICAL FIELD
The present disclosure relates to electric vehicles (EVs), specifically to systems for isolating the battery pack from other vehicle components to ensure safety and reliability under various operational conditions.
BACKGROUND
Electric vehicles (EVs) have emerged as a pivotal technology in the transition towards cleaner transportation. The essential most component of EV technology is the battery pack, a complex assembly of high-voltage batteries that store and deliver the electrical energy necessary to power the vehicle. While the benefits of EVs are substantial, including reduced emissions and increased energy efficiency, the integration of high-voltage battery systems presents unique challenges, particularly regarding safety and reliability. An aspect of addressing the challenges lies in effectively isolating the battery pack from other components of the electric vehicle, especially under various conditions such as mounting/dismounting, overvoltage, undervoltage, overcurrent, and temperature anomalies.
The need for isolation stems primarily from the safety concerns associated with high-voltage systems. During maintenance activities, such as when mounting or dismounting the battery pack, there is a risk of electric shock if the battery is not adequately isolated. The risk extends to scenarios like vehicle accidents, where compromised battery integrity could lead to dangerous electrical exposure to the vehicle occupants or emergency responders. Electric shock hazards are not the only concern; the high energy stored in the battery packs can also pose fire risks if not properly managed and isolated.
In terms of vehicle operation, overvoltage and undervoltage conditions in the battery pack can have detrimental effects. Overvoltage, which might occur due to malfunctioning charging equipment or internal battery defects, can lead to battery degradation, reduced life span, and in extreme cases, thermal runaway – a condition where the battery becomes excessively hot and can ignite. On the other hand, undervoltage conditions, often resulting from deep discharging or faulty battery management systems, can impair vehicle performance and driveability. Isolating the battery pack in such scenarios is crucial to prevent further damage to the battery and other electrical components of the vehicle.
Overcurrent conditions present another significant challenge. The aforesaid conditions can arise from internal short circuits within the battery cells or from external factors such as collision impacts. Effective isolation mechanisms are needed to swiftly disconnect the battery in such events to prevent catastrophic outcomes like fires or explosions.
Temperature anomalies within the battery pack, attributable to either external ambient conditions or internal charging/discharging cycles, necessitate careful thermal management. Excessive heat can degrade battery performance and escalate into safety hazards. Therefore, isolating the battery thermally and electrically is essential to maintain operational integrity and safety.
Several techniques have been developed to address the need for battery pack isolation in EVs. The techniques include physical barriers or enclosures made from non-conductive materials, electrical disconnect systems that can quickly isolate the battery from the electrical system of vehicle in emergencies, and battery management systems (BMS) that constantly monitor and regulate battery conditions.
However, the aforementioned techniques have shortcomings. Physical barriers, while effective in providing insulation and containment, can add significant weight and bulk to the vehicle, impacting its efficiency and range. Electrical disconnect systems, important for immediate isolation, are mechanical in nature and can be prone to wear and failure over time. Moreover, the rapid action required in emergency situations poses a challenge in terms of reliability and speed of the systems.
Battery management systems, equipped with sensors and advanced algorithms, offer a more nuanced approach to isolation by continuously monitoring the state of the battery and pre-emptively addressing issues like overvoltage or overcurrent. However, the reliance on complex software and sensor networks introduces additional points of failure and can complicate vehicle maintenance and diagnostics.
Given such limitations, there is a compelling need for further technical development in the field of battery pack isolation in EVs. Future advancements could encompass the development of new materials and designs for physical isolation that are lighter, more effective, and less intrusive. Improvements in electrical disconnect mechanisms, including faster and more reliable action, are also necessary. Additionally, advancements in battery management system technology, particularly in terms of predictive analytics and fault detection, could significantly enhance the safety and reliability of EVs.
Another area of development is in integrating the isolation systems more seamlessly with the overall design and operation of electric vehicle. Such integration involves the technical aspects and also considerations for user interface, maintenance accessibility, and emergency response protocols.
While the integration of high-voltage battery packs in electric vehicles has been a monumental step forward in automotive technology, significant challenges are associated, which must be addressed to ensure the safety and reliability of the electrical vehicles. Effective isolation of the battery pack from other vehicle components under various conditions is a critical aspect of the challenge. Ongoing research and development in the area are essential to overcoming the current limitations and unlocking the full potential of electric vehicle technology. The development will enhance the safety and performance of EVs and also bolster public confidence in and adoption of the sustainable mode of transportation.
SUMMARY
The aim of the present disclosure is to provide a system to electrically isolate a battery pack of an electric vehicle (EV) to ensure safety and reliability under various operational conditions.
The disclosure relates to a system developed to electrically isolate the battery pack in an electric vehicle (EV). The system includes a battery compartment, a user interface, a switch unit and a power management unit. The battery compartment securely houses the battery pack, ensuring the stability and alignment within the EV. The user interface, integral to the system, can receive specific user input that is indicative of the requirement to isolate the battery pack electrically for various purposes such as safety, maintenance, or emergency situations. The switch unit controls the supply of electric energy from the battery pack. Such control extends to at least one load and includes the power management unit of the EV. The power management unit, upon receiving the user input via the user interface, is programmed to analyze the input and respond by turning OFF the switch unit. The turning OFF of the switch unit serves as the primary mechanism for achieving the electrical isolation of the battery pack. The system, therefore, introduces an approach for enhancing the safety and operational control of electric vehicles, particularly in scenarios requiring the isolation of the battery pack for various functional and safety-related reasons.
In an embodiment, the system comprising a detection module to determine re-installation of the battery pack into the battery compartment.
In an embodiment, the power management unit turns ON the switch unit to reintegrate the battery pack.
In an embodiment, the switch unit comprises at least one of a relay switch, a circuit breaker and a solid-state switch for enabling and disabling the electric energy supply.
In an embodiment, the power management unit controls the switch unit based on a signal from a diagnostic unit that detects a fault condition of the battery pack.
In an embodiment, the battery compartment comprises an ejection unit to eject the battery pack up to a pre-set level to enable electric isolation of the battery pack.
In an embodiment, the power management unit turns OFF the switch unit in at least one event selected from: an overvoltage condition, an undervoltage condition, a overcurrent condition and a temperature anomality.
In an embodiment, the battery compartment comprises a locking mechanism to secure the battery pack.
In an embodiment, the power management unit initiates a diagnostic check upon receiving a new battery pack before reintegration.
Additional aspects, advantages, features and objects of the present disclosure would be made apparent from the drawings and the detailed description of the illustrative embodiments constructed in conjunction with the appended claims that follow.
It will be appreciated that features of the present disclosure are susceptible to being combined in various combinations without departing from the scope of the present disclosure as defined by the appended claims.
BRIEF DESCRIPTION OF DRAWINGS
The summary above, as well as the following detailed description of illustrative embodiments, is better understood when read in conjunction with the appended drawings. For the purpose of illustrating the present disclosure, exemplary constructions of the disclosure are shown in the drawings. However, the present disclosure is not limited to specific methods and instrumentalities disclosed herein. Moreover, those in the art will understand that the drawings are not to scale. Wherever possible, like elements have been indicated by identical numbers.
Embodiments of the present disclosure will now be described, by way of example only, with reference to the following diagrams wherein:
FIG. 1 illustrates a system 100 to electrically isolate a battery pack of an electric vehicle (EV), in accordance with the embodiments of the present disclosure.
FIG. 2 illustrates a step diagram to depict a process for electrically isolating a battery pack of an electric vehicle (EV), in accordance with the embodiments of the present disclosure.
In the accompanying drawings, an underlined number is employed to represent an item over which the underlined number is positioned or an item to which the underlined number is adjacent. A non-underlined number relates to an item identified by a line linking the non-underlined number to the item. When a number is non-underlined and accompanied by an associated arrow, the non-underlined number is used to identify a general item at which the arrow is pointing.
DETAILED DESCRIPTION
The following detailed description illustrates embodiments of the present disclosure and ways in which they can be implemented. Although some modes of carrying out the present disclosure have been disclosed, those skilled in the art would recognise that other embodiments for carrying out or practising the present disclosure are also possible.
The description set forth below in connection with the appended drawings is intended as a description of certain embodiments of a motor of an electric vehicle and is not intended to represent the only forms that may be developed or utilised. The description sets forth the various structures and/or functions in connection with the illustrated embodiments; however, it is to be understood that the disclosed embodiments are merely exemplary of the disclosure that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimised to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention.
While the disclosure is susceptible to various modifications and alternative forms, specific embodiment thereof has been shown by way of example in the drawings and will be described in detail below. It should be understood, however, that it is not intended to limit the disclosure to the particular forms disclosed, but on the contrary, the disclosure is to cover all modifications, equivalents, and alternatives falling within the scope of the disclosure.
The terms “comprise”, “comprises”, “comprising”, “include(s)”, or any other variations thereof, are intended to cover a non-exclusive inclusion, such that a setup, system that comprises a list of components or steps does not include only those components or steps but may include other components or steps not expressly listed or inherent to such setup or system. In other words, one or more elements in a system or apparatus preceded by “comprises... a” does not, without more constraints, preclude the existence of other elements or additional elements in the system or apparatus.
In the following detailed description of the embodiments of the disclosure, reference is made to the accompanying drawings and which are shown by way of illustration specific embodiments in which the disclosure may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the disclosure, and it is to be understood that other embodiments may be utilized and that changes may be made without departing from the scope of the present disclosure. The following description is, therefore, not to be taken in a limiting sense.
The present disclosure will be described herein below with reference to the accompanying drawings. In the following description, well known functions or constructions are not described in detail since they would obscure the description with unnecessary detail.
FIG. 1 illustrates a system 100 to electrically isolate a battery pack of an electric vehicle (EV), in accordance with the embodiments of the present disclosure. The system 100 comprises a battery compartment 102, a user interface 104, a switch unit 106, a power management unit 108 and other known components of power isolation system/apparatus.

In an embodiment, the battery compartment 102 houses the battery pack, providing a secure and stable environment for the optimal functioning of the EV. In such configuration, the battery compartment 102 is constructed using materials that offer high electrical insulation properties, thereby contributing significantly to the overall safety of the system 100. The battery compartment 102 accommodates the specific dimensions and weight of the battery pack, ensuring a snug fit that mitigates the risk of movement or misalignment during the operation of the EV. Furthermore, the battery compartment 102 comprises thermal management features to maintain an optimal temperature range, safeguarding the battery pack from extremes of temperature that could affect the performance and longevity. Ventilation mechanisms are also incorporated into the battery compartment 102, allowing for the dissipation of heat and gases that may be generated by the battery pack during charging or discharging processes. The construction of battery compartment 102 also takes into consideration the need for protection against environmental factors such as moisture, dust, and vibrations, thereby enhancing the durability of the battery pack. Additionally, the battery compartment 102 includes safety features such as fire-retardant materials and emergency venting pathways to address hazards. Accessibility for maintenance and inspection purposes is also a key aspect of the battery compartment 102, ensuring that technicians can easily access the battery pack for routine checks or repairs without compromising the structural integrity or safety of the system.

In an embodiment, the user interface 104 receives a user input for the purpose of isolating the battery pack in the EV. The user interface 104 is an integral component of the system 100 to maintain the electrical safety and operational integrity of the EV by controlling the connection between the battery pack and the electrical systems of EV. The user interface 104 can be implemented in various forms, including but not limited to, physical buttons, touchscreen controls, or voice-activated commands, to enhance user accessibility and ease of operation. Upon activation, the user input received by the user interface 104 is transmitted to the power management unit 108, which then processes the user input to initiate a sequence of actions leading to the isolation of the battery pack. The primary function of the user interface 104 in the current context is to provide a direct and intuitive means for the user to engage the electrical isolation mechanism. Such feature is particularly important in scenarios where immediate disconnection of the battery pack is necessary, such as in maintenance situations, emergency interventions, or as a safety precaution during vehicle servicing. The implementation of user interface 104 in the system 100 enhances user interaction with EV safety features, thereby making the operation of EVs more secure and user-friendly.

In an embodiment, the switch unit 106 which plays a pivotal role in managing the flow of electric energy within the EV. The switch unit 106 enables and/or disables the supply of electric energy from the battery pack to at least one load, as well as to the power management unit 108. Such configuration allows for a controlled and selective distribution of power based on the operational requirements of the EV. The power management unit 108, integral to system 100, analyses the user input, which is received through the user interface 104. Upon receipt of user input, signaling a need for isolation, the power management unit 108 processes the information and executes a command to turn OFF the switch unit 106. The act of turning OFF the switch unit 106 effectively disrupts the flow of electric energy from the battery pack, thereby achieving the desired state of electrical isolation. The feature is paramount in ensuring the safety and maintenance of the EV, especially in circumstances necessitating an immediate cessation of power flow from the battery pack, such as during maintenance operations, in emergency situations, or when the vehicle is not in use. The system 100 provides a mechanism that enhances the overall safety of the EV and also contributes to the longevity and reliability of the battery pack by preventing unwanted discharge or electrical hazards that could arise from uncontrolled power flow.

In an embodiment, the system 100 may comprise a detection module to determine the re-installation of the battery pack into the battery compartment 102. The detection module is integral to the functionality of the system 100, providing information regarding the status of the battery pack. When the battery pack is removed for maintenance, replacement, or other purposes, the detection module actively monitors the battery compartment 102. Upon re-installation of the battery pack into the battery compartment 102, the detection module identifies the change in status. The information is then communicated to the relevant components of the system 100, ensuring that the battery pack is correctly recognized and integrated into the power system of EV.

In an embodiment, the system 100 may feature the power management unit 108 that turn ON the switch unit 106 to reintegrate the battery pack. Such aspect of the system 100 is important for re-establishing the electric connection between the battery pack and the power system of EV following a period of electrical isolation or battery pack removal. Upon detection of the re-installation of the battery pack by the detection module, the power management unit 108 responds by activating the switch unit 106. Such activation reconnects the battery pack, allowing the battery pack to resume supplying electric energy to the EV. Through such mechanism, the power system of EV remains flexible and responsive to maintenance and safety requirements, while also maintaining a seamless operation of the electrical components of EV.

In an embodiment, the switch unit 106 may comprise at least one of a relay switch, a circuit breaker, and a solid-state switch for enabling and disabling the electric energy supply. Such diversity in the types of switches used within the switch unit 106 allows for a versatile approach for managing the electric energy supply from the battery pack. Each type of switch offers distinct advantages. For instance, a relay switch provides effective control and is suitable for high-power applications, a circuit breaker offers protection against overcurrent and short circuits, and a solid-state switch allows for rapid and precise control with minimal wear and tear. The inclusion of the varying types of switches within the switch unit 106 enables catering to different operational and safety requirements, thereby enhancing the overall functionality and reliability of the power management system of EV.

In an embodiment, the power management unit 108 may control the switch unit 106 based on a signal from a diagnostic unit that detects a fault condition of the battery pack. Such aspect of the system 100 maintains the safety and integrity of the battery pack and, by extension, the EV. The diagnostic unit continually monitors the condition of the battery pack, identifying any faults or anomalies. Upon detection of a fault condition, such as a cell imbalance, overheating, or degradation, the diagnostic unit sends a signal to the power management unit 108. In response to the signal, the power management unit 108 takes appropriate action by controlling the switch unit 106. The aforesaid controlling may involve isolating the battery pack to prevent further damage or to facilitate safe maintenance and repair activities.

In an embodiment, the battery compartment 102 may comprise an ejection unit to eject the battery pack up to a pre-set level to enable electric isolation of the battery pack. The incorporation of the ejection unit in the battery compartment 102 facilitates the process of removing and isolating the battery pack. When electric isolation is necessary, either for maintenance, replacement, or safety reasons, the ejection unit mechanically lifts the battery pack to a predetermined level. Through such mechanism, the battery pack is partially disengaged from the normal operating position within the battery compartment 102, effectively breaking the electric connection and achieving isolation.

In an embodiment, the switch unit 106 in at least one event may be selected from: an overvoltage condition, an undervoltage condition, an overcurrent condition, and a temperature anomaly. Such feature of the system 100 depicts the ability to respond to various abnormal operating conditions that could pose a risk to the battery pack or the EV. In events such as overvoltage, undervoltage, overcurrent, or abnormal temperature conditions, the power management unit 108 acts promptly by turning OFF the switch unit 106. Such action effectively isolates the battery pack from the electrical system of EV, preventing damage or safety hazards.

In an embodiment, the battery compartment 102 may comprise a locking mechanism to secure the battery pack. The presence of the locking mechanism in the battery compartment 102 is a safety and security feature. The locking mechanism make sure that the battery pack is held securely in place during the operation of the EV, preventing unintended movement or dislodgement that could lead to electrical disconnections or damage. Additionally, the locking mechanism provides an added layer of security against unauthorized access or theft of the battery pack. The ability to securely lock the battery pack within the battery compartment 102 is especially important given the high value and nature of the battery in the overall functionality of the EV.

In an embodiment, the power management unit 108 may initiate a diagnostic check upon receiving a new battery pack before reintegration. Such feature of the system 100 enhance the compatibility and safety of the new battery pack prior to the integration into the power system of EV. When the new battery pack is installed, the power management unit 108 conducts the diagnostic check. Such check assesses various parameters of the battery pack, such as its voltage, current capacity, temperature profile, and overall health. The purpose of diagnostic check is to confirm that the new battery pack meets the necessary specifications and is in proper working condition. Only after passing the diagnostic check is the battery pack reintegrated into the power system of EV. The process helps prevent issues related to the integration of an incompatible or faulty battery pack.
FIG. 2 illustrates a step diagram to depict a process for electrically isolating a battery pack of an electric vehicle (EV), in accordance with the embodiments of the present disclosure. The system 100 incorporates input means 104, through which user inputs are received (at step 1) and subsequently relayed to the power management unit 108 at step 2. The power management unit 108 manages the power needs of the system 100 (at step 3), including the controlled distribution of power to various components as required. Incorporated within the power management unit 108 is the switch unit 106, responsible for establishing or interrupting the circuitry based on commands received either from the user inputs through the input means 104 or from automated system feedback (at step 4). Feedback is recognized by the power management unit when certain operational parameters are met or exceeded, initiating a decision-making process within the unit. Furthermore, there is a provision for a disabled connection within the battery compartment 102, a safety feature that allows for the electrical isolation of the battery to facilitate safe maintenance and emergency handling procedures. The disabled connection can be actuated manually or automatically, based on signals processed by the power management unit 108, which assesses the status of the battery and the overall system health.

As used herein, the terms ‘electric vehicle’, ‘2W-EVs’, ‘electric two-wheeler’, ‘EV’, ‘EVs’, and ‘two-wheel electric vehicle’ are used interchangeably and refer to any vehicle having stored electrical energy, including that vehicle capable of being charged from an external electrical power source. This may include vehicles having batteries that are exclusively charged from an external power source, as well as hybrid vehicles which may include batteries capable of being at least partially recharged via an external power source.

As used herein, the terms ‘swappable battery’ and ‘replaceable battery’ are used interchangeably and refer to a battery pack that facilitates exchanging discharged batteries for charged ones when power gets drained out.

As used herein, the term ‘battery pack’ refers to a power supply unit of an electric vehicle. The battery pack includes at least one battery-cell array.

As used herein, the terms ‘battery-cell array’ and ‘cell array’ are used interchangeably and refer to a set of electrically connected individual battery cells, that may be configured in a series, parallel or a mixture of both to deliver the desired voltage, capacity, or power density.

As used herein, the term “engagement portion” refers to a connector that electrically connects the components and battery pack such that an electric current runs between them.
As used herein, the term “rear part” refers to a vehicle seat position apart from the left or right position of the vehicle.
In the description of the present invention, it is also to be noted that, unless otherwise explicitly specified or limited, the terms “disposed,” “mounted,” and “connected” are to be construed broadly, and may for example be fixedly connected, detachably connected, or integrally connected, either mechanically or electrically. They may be connected directly or indirectly through intervening media, or they may be interconnected between two elements. The specific meaning of the above terms in the present invention can be understood in specific cases to those skilled in the art.
Modifications to embodiments and combination of different embodiments of the present disclosure described in the foregoing are possible without departing from the scope of the present disclosure as defined by the accompanying claims. Expressions such as “including”, “comprising”, “incorporating”, “have”, “is” used to describe and claim the present disclosure are intended to be construed in a non- exclusive manner, namely allowing for items, components or elements not explicitly described also to be present. Reference to the singular is also to be construed to relate to the plural where appropriate.
Although embodiments have been described with reference to a number of illustrative embodiments thereof, it should be understood that numerous other modifications and embodiments can be devised by those skilled in the art that will fall within the spirit and scope of the principles of this disclosure. More particularly, various variations and modifications are possible in the component parts and/or arrangements of the subject combination arrangement within the scope of the present disclosure, the drawings and the appended claims. In addition to variations and modifications in the component parts and/or arrangements, alternative uses will also be apparent to those skilled in the art.

,CLAIMS:WE CLAIM:
1. A system (100) to electrically isolate a battery pack of an electric vehicle (EV), the system (100) comprising:
a battery compartment (102) houses the battery pack;
a user interface (104) receives a user input to isolate the battery pack; and
a switch unit (106) enables and/or disables supply of electric energy from the battery pack to at least one load and a power management unit (108), wherein the power management unit (108) analyzes the received user input to turn OFF the switch unit (106) to electrically isolate the battery pack.
2. The system (100) as claimed in claim 1, comprising a detection module to determine re-installation of the battery pack into the battery compartment (102).
3. The system (100) as claimed in claim 2, wherein the power management unit (108) turns ON the switch unit (106) to reintegrate the battery pack.
4. The system (100) as claimed in claim 1, wherein the switch unit (106) comprises at least one of a relay switch, a circuit breaker and a solid-state switch for enabling and disabling the electric energy supply.
5. The system (100) as claimed in claim 1, wherein the power management unit (108) controls the switch unit (106) based on a signal from a diagnostic unit that detects a fault condition of the battery pack.
6. The system (100) as claimed in claim 1, wherein the battery compartment (102) comprises an ejection unit to eject the battery pack up to a pre-set level to enable electric isolation of the battery pack.
7. The system (100) as claimed in claim 1, wherein the power management unit (108) turns OFF the switch unit in at least one event selected from: an overvoltage condition, an undervoltage condition, a overcurrent condition and a temperature anomality.
8. The system (100) as claimed in claim 1, wherein the battery compartment (102) comprises a locking mechanism to secure the battery pack.
9. The system (100) as claimed in claim 1, wherein the power management unit (108) initiates a diagnostic check upon receiving a new battery pack before reintegration.