DESC:SWAPPABLE POWER PACK FOR ELECTRIC VEHICLE
CROSS-REFERENCE TO RELATED APPLICATIONS
The present application claims priority from Indian Provisional Patent Application No. 202321037172 filed on 30/05/2023, the entirety of which is incorporated herein by a reference.
TECHNICAL FIELD
The present disclosure generally relates to swappable power packs. The present disclosure particularly relates to a swappable power pack for an electric vehicle.
BACKGROUND
Recently, there has been a rapid development in electric vehicles because of their ability to resolve pollution-related problems and serve as a clean mode of transportation. Generally, electric vehicles include a battery pack, power pack, and/or combination of electric cells for storing electricity required for the propulsion of the vehicles. The electrical power stored in the battery pack of the electric vehicle is supplied to the traction motor for moving the electric vehicle. Once the electrical power stored in the battery pack of the electric vehicle is depleted, the battery pack is required to be charged from a power source or by replacing the depleted battery pack with a fully charged battery pack.
The replaceable battery packs are also known as swappable battery packs and resolve the problems of charger availability and range anxiety associated with fixed battery packs. Moreover, the swappable battery packs may also solve the problem high initial cost of ownership of the electric vehicles. Since the battery is the most expensive component of the electric vehicle, the cost associated with the ownership of the battery pack may be eliminated by getting a swappable battery as a service.
However, the swappable battery packs also require infrastructure in terms of battery swapping stations. The battery swapping stations convert the electrical energy received from the grid to charge the swappable battery packs. Furthermore, if the swappable battery pack is required to be charged with a charger, while being in the electric vehicle, the charger would also require a suitable power converter to convert the electrical energy received from the power source (grid) to charge the swappable battery pack. Moreover, the domestic uninterrupted power supply systems have also recently started being used for charging the swappable battery packs, while delivering power backup as and when required. However, such domestic uninterrupted power supply systems are costly and increase the ownership cost of the electric vehicle. Moreover, a lot of electronic components are redundant on the charging equipment side when the swappable battery is being charged. Such redundancy increases the overall cost of the swappable battery ecosystem and hinders the use of swappable battery packs as clean energy storage solutions for mobility and fixed applications.
Therefore, there exists a need for an improved swappable battery pack that overcomes one or more problems associated as set forth above.
SUMMARY
An object of the present disclosure is to provide a swappable power pack for an electric vehicle.
Another object of the present disclosure is to provide a swappable power pack with an integrated charging unit.
In accordance with an aspect of the present disclosure, there is provided a swappable power pack for an electric vehicle. The power pack comprises at least one battery module, a battery management system, an auxiliary charging unit, and a DC input/output. The auxiliary charging unit is configured to convert AC power received from an AC power source into DC power, to charge the at least one battery module, when the swappable power pack is connected to the AC power source.
The present disclosure provides a swappable power pack for the electric vehicle. Beneficially, the swappable power pack of the present disclosure comprises an integrated charging unit. Beneficially, the swappable power pack of the present disclosure eliminates the need for power converters in external AC charger of the swappable battery pack. Furthermore, the swappable power pack of the present disclosure is advantageous in terms of reducing the costs of the clean energy storage ecosystem. Beneficially, the swappable power pack of the present disclosure is advantageous in terms of eliminating the requirement of a domestic uninterrupted power supply specifically meant for charging the swappable battery pack of the electric vehicle. Beneficially, the swappable power pack of the present disclosure may also be charged at DC fast charging swapping station along with the home charging.
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:
Figure 1 illustrates a block diagram of a swappable power pack for an electric vehicle, in accordance with an embodiment of the present disclosure.
Figure 2 illustrates a circuit diagram of the swappable power pack for an electric vehicle, in accordance with another embodiment 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 recognize that other embodiments for carrying out or practicing 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 swappable power pack and is not intended to represent the only forms that may be developed or utilized. 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 minimized 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, or 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 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.
As used herein, the terms “electric vehicle”, “EV”, and “EVs” are used interchangeably and refer to any vehicle having stored electrical energy, including the 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. Additionally, it is to be understood that the ‘electric vehicle’ as used herein includes electric two-wheelers, electric three-wheelers, electric four-wheelers, electric pickup trucks, electric trucks, and so forth.
As used herein, the terms “battery pack”, “battery”, and “power pack” are used interchangeably and refer to multiple individual battery cells connected to provide a higher combined voltage or capacity than what a single battery can offer along with the necessary electronic components and circuitry required to do so. The battery pack is designed to store electrical energy and supply it as needed to various devices or systems. Battery packs, as referred herein may be used for various purposes such as power electric vehicles and other energy storage applications. Furthermore, the battery pack may include additional circuitry, such as a battery management system (BMS), to ensure the safe and efficient charging and discharging of the battery cells. The battery pack comprises a plurality of cell arrays which in turn comprises a plurality of battery cells.
As used herein, the term “battery module” refers to a plurality of individual battery cells connected to provide a higher combined voltage or capacity. The battery module is used to store the electrical energy and provide the electrical energy when required.
As used herein, the term “auxiliary charging unit” refers to a power electronic device that converts the alternating current (AC) to direct current (DC). Preferably, the auxiliary charging unit is a forward converter that uses simplified architecture to efficiently convert AC power into DC power. Beneficially, the forward converter is more efficient than conventional flyback converters. More beneficially, the auxiliary charging unit is integrated into the power pack.
As used herein, the term “battery management system” refers to an electronic device that manages the charging and discharging of the plurality of battery cells of the battery module. The battery management system may monitor the voltage and current during the charging and discharging process. Furthermore, the battery management system may monitor the temperature and state of charge of the plurality of battery cells of the battery module. Moreover, the battery management system may also perform cell balancing and provide protection to the plurality of battery cells from overcharging/over discharging.
As used herein, the terms “control unit” and “controller” are used interchangeably and refer to a computational element that is operable to respond to and process instructions that control the electronic components in the swappable power pack. Optionally, the control unit may be a micro-controller, a complex instruction set computing (CISC) microprocessor, a reduced instruction set (RISC) microprocessor, a very long instruction word (VLIW) microprocessor, a digital signal processor, or any other type of processing unit. Furthermore, the term “microprocessor” may refer to one or more individual processors, processing devices, and various elements associated with a processing device that may be shared by other processing devices. Furthermore, the microprocessor may be designed to handle real-time tasks with high performance and low power consumption. Furthermore, the microprocessor may comprise custom and/or proprietary processors.
As used herein, the term “AC power source” refers to an equipment supplying AC power for charging the swappable power pack. The AC power source may supply domestic AC power with a voltage of 180-240V and 50 Hz frequency.
As used herein, the term “DC input/output” refers to the input and output terminal supporting DC power input to the swappable power pack for DC fast charging of the swappable power pack and DC power output from the swappable power pack to a DC load connected to the swappable power pack.
As used herein, the term “residual current detection module” refers to a safety module used in the swappable power pack that monitors the current balance, detects leakage current and triggers disconnect to prevent the user from getting an electrical shock, when the swappable power pack is connected to the AC power source.
As used herein, the term “diode” refers to a semiconductor device that typically comprises two terminals and allows the flow of current only in one direction.
As used herein, the term “AC-DC converter” refers to a device that converts alternating current (AC) to direct current (DC). The AC-DC converter converts the high-voltage AC power from the AC power source to the DC power required for charging the swappable power pack.
As used herein, the term “DC-DC converter” refers to a device that converts direct current (DC) from one voltage level to another. The DC-DC converter is responsible for converting the high-voltage DC power from the AC-DC converter to the lower voltage DC power required to charge the swappable power pack.
As used herein, the term “high-frequency transformer” refers to a transformer that operates at a higher frequency than a traditional transformer and efficiently steps down one voltage to another voltage. Beneficially, the high-frequency transformer is small in size and lightweight compared to a traditional transformer.
As used herein, the term “communicably coupled” refers to a bi-directional connection between the various components of the swappable power pack. The bi-directional connection between the various components of the swappable power pack enables the exchange of data between two or more components of the swappable power pack.
As used herein, the terms “DC link capacitor bank”, “DC link capacitor”, “DC bus capacitor”, and “capacitor” are used interchangeably and refer to a plurality of capacitors that are used to smooth out the fluctuating DC voltage between different components of the swappable power pack. The DC link capacitor bank functions to smooth out the power, stabilize the DC bus voltage, and act as energy storage for transient loads.
As used herein, the term “gate drivers” refers to electronic components responsible for controlling the switching of Metal Oxide Semiconductor Field Effect Transistor (MOSFET) which forms switches in the power converter. It is to be understood that the gate drivers convert the control signal into precise voltage and current pulses required to turn the power electronics switches on and off rapidly. The switches may control the flow of the electric current to the battery module, for charging the battery module, when the swappable power pack is connected to the AC power source.
As used herein, the terms “switches” and “plurality of switch” are used interchangeably and refer to power electronics devices that control the flow of electric power from the auxiliary charging unit to the battery module. Beneficially, MOSFETs are used as switches in the integrated power converter as the MOSFETs have low on-state resistance that helps in reducing power losses and increasing the overall efficiency of the integrated power converter. The switches may be at least one of MOSFETs, IGBTs, transistors, or a combination thereof.
As used herein, the terms “plurality of sensors” “sensor arrangement” and “sensors” are used interchangeably and refer to a configuration of sensors in the system and/or arrangement to measure, monitor, or detect specific parameters, conditions, and/or events. The plurality of sensors may comprise current sensors, voltage sensors, hall effect sensors, insulation monitoring sensors, or a combination thereof.
Figure 1, in accordance with an embodiment, describes a swappable power pack 100 for an electric vehicle. The power pack 100 comprises at least one battery module 102, a battery management system 104, an auxiliary charging unit 106, and a DC input/output 108. The auxiliary charging unit 106 is configured to convert AC power received from an AC power source into DC power, to charge the at least one battery module 102, when the swappable power pack 100 is connected to the AC power source.
The present disclosure provides a swappable power pack 100 for the electric vehicle. Beneficially, the swappable power pack 100 of the present disclosure comprises an integrated auxiliary charging unit 106. Beneficially, the swappable power pack 100 of the present disclosure eliminates the need for power converters in external AC charger of the swappable battery pack 100. Furthermore, the swappable power pack 100 of the present disclosure is advantageous in terms of reducing the costs of the clean energy storage ecosystem. Beneficially, the swappable power pack 100 of the present disclosure is advantageous in terms of eliminating the requirement of a domestic uninterrupted power supply specifically meant for charging the swappable battery pack 100 of the electric vehicle. Beneficially, the swappable power pack 100 of the present disclosure may also be charged at DC fast charging swapping station along with the home charging.
In an embodiment, the battery management system 104 manages charging and discharging of the at least one battery module 102. Beneficially, the battery management system 104 interacts with a plurality of battery cells in the battery module 102 to monitor and manage the charging and discharging of the battery module 102. Beneficially, the battery management system 104 may prevent the overcharging and over discharging of the battery module 102.
In an embodiment, the battery management system 104 monitors a plurality of parameters associated with the at least one battery module 102. It is to be understood that the plurality of parameters associated with the at least one battery module 102 may include charging voltage, charging current, discharging voltage, discharging current, temperature, state of charge, state of health and so on. Beneficially, the battery management system 104 manages the charging and discharging of the at least one battery module 102 based on the plurality of parameters associated with the at least one battery module 102.
In an embodiment, the battery management system 104 is communicably coupled to the auxiliary charging unit 106, to communicate the monitored plurality of parameters associated with the at least one battery module 102. Beneficially, the battery management system 104 communicate the monitored plurality of parameters associated with the at least one battery module 102 to the auxiliary charging unit 106 for efficient and optimized charging and discharging of the at least one battery module 102.
In an embodiment, the swappable power pack 100 comprises a DC link capacitor bank 110 connected with the battery management system 104 to minimize voltage ripple between the battery management system 104 and the auxiliary charging unit 106. Beneficially, the DC link capacitor bank 110 absorbs the periodic voltage and/or current spikes between the battery management system 104 and the auxiliary charging unit 106. It would be appreciated that the DC link capacitor bank 110 would absorb the excess amount of voltage and/or current between the battery management system 104 and the auxiliary charging unit 106, and would supply the same to the auxiliary charging unit 106 when there is a drop in voltage and/or current between the battery management system 104 and the auxiliary charging unit 106.
In an embodiment, the DC link capacitor bank 110 is connected to the DC input/output 108 to minimize voltage ripple between the battery management system 104 and the DC input/output 108, when the swappable power pack 100 is connected to a DC power source or a DC load. It would be appreciated that the DC link capacitor bank 110 would absorb the excess amount of voltage and/or current between the battery management system 104 and the DC input/output 108, and would supply the same to the DC input/output 108 when there is a drop in voltage and/or current between the battery management system 104 and the DC input/output 108.
In an embodiment, the auxiliary charging unit 106 comprises an AC connector 112, a residual current detection module 114, an AC-DC converter 116, a DC link filter 124, a DC-DC converter 118 and a control unit 120. Beneficially, the auxiliary charging unit 106 enables charging of the swappable power pack 100 anywhere using the AC power source such as a domestic AC power outlet. Beneficially, the auxiliary charging unit 106 eliminates the requirement of the domestic uninterrupted power supply specifically meant for charging the swappable power pack 100.
In an embodiment, the AC connector 112 is configured to electrically connect the AC-DC converter 116 with the AC power source. Beneficially, the AC connector 112 provide electrical path for transfer of AC power from the AC power source to the AC-DC converter 116 of the swappable power pack 100.
In an embodiment, the residual current detection module 114 is communicably coupled to the control unit 120 and configured to detect residual current in the swappable power pack 100, when the swappable power pack 100 is connected to the AC power source. Beneficially, the residual current detection module 114 prevents the user from getting an electrical shock in case of a fault (leakage current), when the swappable power pack 100 is connected to the AC power source.
In an embodiment, the AC-DC converter 116 comprises a plurality of diodes D1, D2, D3, D4 in a full bridge configuration to convert AC power received from the AC power source into DC voltage for the DC-DC converter 118. Beneficially, the plurality of diodes D1, D2, D3, D4 operate in a defined sequence to convert the AC power received from the AC power source into the DC voltage for the DC-DC converter 118. Beneficially, the plurality of diodes D1, D2, D3, D4 efficiently convert the AC power received from the AC power source into the DC voltage for the DC-DC converter 118.
In an embodiment, the AC-DC converter 116 comprises an inductor I1, a switch S1 and a diode D5 in a boost converter configuration to improve power quality of the DC voltage for the DC-DC converter 118. Beneficially, the boost converter configuration of the inductor I1, the switch S1 and the diode D5 reduce losses in the AC-DC converter 116.
In an embodiment, the DC-DC converter 118 comprises a high-frequency transformer 122 with a primary winding 122a, a secondary winding 122b and a tertiary winding 122c. Beneficially, the high-frequency transformer 122 efficiently steps down the DC voltage for the DC-DC converter 118.
In an embodiment, the DC-DC converter 118 comprises a switch S2 connected with the primary winding 122a, wherein the switch S2 is configured to convert the DC voltage for the DC-DC converter 118 into a high-frequency AC input power for the high-frequency transformer 122. It is to be understood that the switch S2 turns on and off to create a flow of high-frequency AC input power from the AC-DC converter 116 to the primary winding 122a. Such flow of high-frequency AC input power creates magnetic field in the transformer core. Such magnetic field induced by the current in the primary winding 112a generates a voltage in the secondary winding 122b.
In an embodiment, the DC-DC converter 118 comprises a diode D6 connected with the tertiary winding 122c, wherein the diode D6 and the tertiary winding 122c are configured to discharge a residual power present between the primary winding 122a and the secondary winding 122b. It is to be understood that the tertiary winding 122c and the diode D6 act in conjunction to provide a path for magnetizing current of the primary winding 122a to return to AC-DC converter 116 when the switch S2 turns off. This ensures that transformer core of the high-frequency transformer 122 resets completely before the next switching cycle, maintaining efficient operation.
In an embodiment, the high-frequency transformer 122 steps down the high-frequency AC input power to generate a high-frequency AC output power. Beneficially, the high-frequency transformer 122 also provides galvanic isolation between the AC power source and the at least one battery module 102.
In an embodiment, the DC-DC converter 118 comprises a rectifier diode D7, a freewheeling diode D8 and an inductor I2 configured to rectify the high-frequency AC output power into the DC power, to charge the at least one battery module 102. Beneficially, the rectified DC power is supplied to the battery management system 104 to charge the at least one battery module 102. It is to be understood that the rectifier diode D7 rectifies the high-frequency AC output power induced in the secondary winding to the DC power. Furthermore, the freewheeling diode D8 becomes forward-biased during the switch-off phase to provide a path for the power stored in the inductor I2.
In an embodiment, the control unit 120 is configured to control the operation of the residual current detection module 114, the AC-DC converter 116, and the DC-DC converter 118. Beneficially, the control unit 120 is communicably coupled to the components of the residual current detection module 114, the AC-DC converter 116, and the DC-DC converter 118 to control their operation. It is to be understood that the control unit 120 may control the operation of the diodes D1 to D8, the switches S1, S2 and the inductors I1, I2 to control the operation of the AC-DC converter 116, and the DC-DC converter 118.
In an embodiment, the DC link filter 124 is connected between the AC-DC converter 116 and the DC-DC converter 118 to minimize voltage ripple. Beneficially, the DC link filter 124 absorbs the excess amount of voltage and/or current between the AC-DC converter 116 and the DC-DC converter 118, and would supply the same to the DC-DC converter 118 when there is a drop in voltage and/or current between the AC-DC converter 116 and the DC-DC converter 118.

In an embodiment, the DC input/output 108 is connected to the DC power source to charge the at least one battery module 102. Beneficially, the swappable battery pack 100 is capable of being charged at DC fast charging swapping stations. It is to be understood that the auxiliary charging unit 106 of the swappable battery pack 100 is bypassed during DC charging of the swappable battery pack 100.
In an embodiment, the DC input/output 108 is connected to the DC load to supply power stored in the at least one battery module 102. Beneficially, the auxiliary charging unit 106 of the swappable battery pack 100 is bypassed during DC operation of the swappable battery pack 100.
Figure 2, in accordance with an embodiment, describes the swappable power pack 100 for the electric vehicle. The power pack 100 comprises the at least one battery module 102, the battery management system 104, the auxiliary charging unit 106, and the DC input/output 108. The auxiliary charging unit 106 is configured to convert AC power received from the AC power source into the DC power, to charge the at least one battery module 102, when the swappable power pack 100 is connected to the AC power source. Furthermore, the battery management system 104 manages charging and discharging of the at least one battery module 102. Furthermore, the battery management system 104 monitors the plurality of parameters associated with the at least one battery module 102. Furthermore, the battery management system 104 is communicably coupled to the auxiliary charging unit 106, to communicate the monitored plurality of parameters associated with the at least one battery module 102. Furthermore, the swappable power pack 100 comprises the DC link capacitor bank 110 connected with the battery management system 104 to minimize voltage ripple between the battery management system 104 and the auxiliary charging unit 106. Furthermore, the DC link capacitor bank 110 is connected to the DC input/output 108 to minimize voltage ripple between the battery management system 104 and the DC input/output 108, when the swappable power pack 100 is connected to the DC power source or the DC load. Furthermore, the auxiliary charging unit 106 comprises the AC connector 112, the residual current detection module 114, the AC-DC converter 116, the DC link filter 124, the DC-DC converter 118 and the control unit 120. Furthermore, the AC connector 112 is configured to electrically connect the AC-DC converter 116 with the AC power source. Furthermore, the residual current detection module 114 is communicably coupled to the control unit 120 and configured to detect residual current in the swappable power pack 100, when the swappable power pack 100 is connected to the AC power source. Furthermore, the AC-DC converter 116 comprises the plurality of diodes D1, D2, D3, D4 in the full bridge configuration to convert AC power received from the AC power source into DC voltage for the DC-DC converter 118. Furthermore, the AC-DC converter 116 comprises the inductor I1, the switch S1 and the diode D5 in the boost converter configuration to improve power quality of the DC voltage for the DC-DC converter 118. Furthermore, the DC-DC converter 118 comprises the high-frequency transformer 122 with the primary winding 122a, the secondary winding 122b and the tertiary winding 122c. Furthermore, the DC-DC converter 118 comprises the switch S2 connected with the primary winding 122a, wherein the switch S2 is configured to convert the DC voltage for the DC-DC converter 118 into the high-frequency AC input power for the high-frequency transformer 122. Furthermore, the DC-DC converter 118 comprises the diode D6 connected with the tertiary winding 122c, wherein the diode D6 and the tertiary winding 122c are configured to discharge the residual power present between the primary winding 122a and the secondary winding 122b. Furthermore, the high-frequency transformer 122 steps down the high-frequency AC input power to generate the high-frequency AC output power. Furthermore, the DC-DC converter 118 comprises the rectifier diode D7, the freewheeling diode D8 and the inductor I2 configured to rectify the high-frequency AC output power into the DC power, to charge the at least one battery module 102. Furthermore, the control unit 120 is configured to control the operation of the residual current detection module 114, the AC-DC converter 116, and the DC-DC converter 118. Furthermore, the DC link filter 124 is connected between the AC-DC converter 116 and the DC-DC converter 118 to minimize voltage ripple.

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 combinations 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”, and “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 swappable power pack (100) for an electric vehicle, wherein the power pack (100) comprises:
- at least one battery module (102);
- a battery management system (104);
- an auxiliary charging unit (106); and
- a DC input/output (108),
wherein the auxiliary charging unit (106) is configured to convert AC power received from an AC power source into DC power, to charge the at least one battery module (102), when the swappable power pack (100) is connected to the AC power source.
2. The swappable power pack (100) as claimed in claim 1, wherein the battery management system (104) manages charging and discharging of the at least one battery module (102).
3. The swappable power pack (100) as claimed in claim 1, wherein the battery management system (104) monitors a plurality of parameters associated with the at least one battery module (102).
4. The swappable power pack (100) as claimed in claim 1, wherein the battery management system (104) is communicably coupled to the auxiliary charging unit (106), to communicate the monitored plurality of parameters associated with the at least one battery module (102).
5. The swappable power pack (100) as claimed in claim 1, wherein the swappable power pack (100) comprises a DC link capacitor bank (110) connected with the battery management system (104) to minimize voltage ripple between the battery management system (104) and the auxiliary charging unit (106).
6. The swappable power pack (100) as claimed in claim 5, wherein the DC link capacitor bank (110) is connected to the DC input/output (108) to minimize voltage ripple between the battery management system (104) and the DC input/output (108), when the swappable power pack (100) is connected to a DC power source or a DC load.
7. The swappable power pack (100) as claimed in claim 1, wherein the auxiliary charging unit (106) comprises an AC connector (112), a residual current detection module (114), an AC-DC converter (116), a DC link filter (124), a DC-DC converter (118) and a control unit (120).
8. The swappable power pack (100) as claimed in claim 7, wherein the AC connector (112) is configured to electrically connect the AC-DC converter (116) with the AC power source.
9. The swappable power pack (100) as claimed in claim 7, wherein the residual current detection module (114) is communicably coupled to the control unit (120) and configured to detect residual current in the swappable power pack (100), when the swappable power pack (100) is connected to the AC power source.
10. The swappable power pack (100) as claimed in claim 7, wherein the AC-DC converter (116) comprises a plurality of diodes (D1, D2, D3, D4) in a full bridge configuration to convert AC power received from the AC power source into DC voltage for the DC-DC converter (118).
11. The swappable power pack (100) as claimed in claim 10, wherein the AC-DC converter (116) comprises an inductor (I1), a switch (S1) and a diode (D5) in a boost converter configuration to improve power quality of the DC voltage for the DC-DC converter (118).
12. The swappable power pack (100) as claimed in claim 7, wherein the DC-DC converter (118) comprises a high-frequency transformer (122) with a primary winding (122a), a secondary winding (122b) and a tertiary winding (122c).
13. The swappable power pack (100) as claimed in claim 7, wherein the DC-DC converter (118) comprises a switch (S2) connected with the primary winding (122a), wherein the switch (S2) is configured to convert the DC voltage for the DC-DC converter (118) into a high-frequency AC input power for the high-frequency transformer (122).
14. The swappable power pack (100) as claimed in claim 7, wherein the DC-DC converter (118) comprises a diode (D6) connected with the tertiary winding (122c), wherein the diode (D6) and the tertiary winding (122c) are configured to discharge a residual power present between the primary winding (122a) and the secondary winding (122b).
15. The swappable power pack (100) as claimed in claim 7, wherein the high-frequency transformer (122) steps down the high-frequency AC input power to generate a high-frequency AC output power.
16. The swappable power pack (100) as claimed in claim 7, wherein the DC-DC converter (118) comprises a rectifier diode (D7), a freewheeling diode (D8) and an inductor (I2) configured to rectify the high-frequency AC output power into the DC power, to charge the at least one battery module (102).
17. The swappable power pack (100) as claimed in claim 7, wherein the control unit (120) is configured to control the operation of the residual current detection module (114), the AC-DC converter (116), and the DC-DC converter (118).
18. The swappable power pack (100) as claimed in claim 7, wherein the DC link filter (124) is connected between the AC-DC converter (116) and the DC-DC converter (118) to minimize voltage ripple.
19. The swappable power pack (100) as claimed in claim 1, wherein the DC input/output (108) is connected to the DC power source to charge the at least one battery module (102).
20. The swappable power pack (100) as claimed in claim 1, wherein the DC input/output (108) is connected to the DC load to supply power stored in the at least one battery module (102).