FIELD OF INVENTION

[001] The present disclosure relates generally to a power-pack assembly and more particularly to a compact power pack assembly that encloses battery and a plurality of high voltage and high current electronic components of an electric vehicle in a single unit that reduces weight, size, and cost while increasing efficiency and power density of an electric vehicle.

BACKGROUND OF THE INVENTION

[002] Conventional packaging of high voltage and high current (HV/HC) electronic components in an electric vehicle requires separate packaging of components such as Battery Pack, Battery Management System (BMS), drivetrain Unit (DTU), Auxiliary Power System (APS), Discharge Protection Switch (DPS), Body Control Unit (BCU) and an Electric Motor. All these components are connected with multiple high voltage (HV) thick and long wires as depicted in FIG. 1 .

[003] Incorporation of such long and thick HV wires in large numbers also requires external routing of the HV wires along the length of the vehicle which are exposed to the external environment. This demands a need for adding an extra layer of safety in form of cable sleeves to protect the HV wires from any hazard such as water, dust, etc. This further adds the complexity, weight, size, and cost of the vehicle. Apart from this, the use of longer HV cables leads to higher voltage drop and EMI/EMC issues. To solve these issues some extra components needs to be added leading to extra cost and weight for the vehicle. Heavier weight of the vehicle results in a lower range as well as acceleration.

[004] Thus, it is highly desirable to arrange all these HV/HC electronic components of the electric vehicle in a manner that reduces voltage drop and EMI/EMC issues associated with prior systems without contributing to additional cost and weight.

OBJECT OF THE INVENTION [005] It is an object of the invention is to provide a compact lightweight power pack assembly having increased power density and enhanced vehicle range.

[006] An another object of the invention is to provide a compact power pack assembly that provides increased efficiency of the vehicle by reducing copper losses and voltage drop.

[007] Yet another object of the invention is to provide a compact power pack assembly that has reduced EMI/EMC issues.

[008] Still another object of the invention is to provide a compact power pack assembly that avoids the use of long thick wires/cables to interconnect the battery pack and the high voltage and high current components of the electric vehicle.

[009] An another object of the invention is provide a compact power pack assembly that protects the battery pack and high voltage and high current electronic components of the electric vehicle from the adverse effect of water and dust without contributing to extra cost and weight.

[0010] An another object of the invention is provide a compact power pack assembly that reduces the complexity of the packaging of electronic components of an electric vehicle and eases handling and manufacturing thereof.

[0011 ] Other objects and advantages of the system of the present disclosure will be more apparent from the following description when read in conjunction with the accompanying figures, which are not intended to limit the scope of the present disclosure.

SUMMARY OF THE INVENTION

[0012] In a one embodiment of the present invention, a compact power-pack assembly for an electric vehicle is provided. The assembly comprises a battery pack (101 ) containing at least two cell array (101 a, 101 b), a Battery Management System (BMS) (102) mounted over top of the battery pack (101 ), a drivetrain unit (DTU) (103) disposed on one side of the battery pack (101 ), a discharge protection switch (DPS) (104) disposed on a side of the Drive Train Unit (103) and is in electrical connection with the Battery Management System (BMS) (102) and an Auxiliary Power System (APS) (105) disposed on a side of Drive Train Unit (103) beside the discharge protection switch (DPS) (104).

[0013] In one embodiment of the invention, each of the cell array (101 a, 101 b) comprises a plurality of single cells which are electrically and mechanically connected in series in a row and arranged in parallel in a closely packed configuration in a battery pack, and the Battery Management System (BMS) (102) is configured to manage the current input and output from the battery pack (101 ). The drivetrain unit (DTU) (103) is configured to control an electric motor according to an output received from the Battery Management System (BMS) (102). The discharge protection switch (DPS) is configured to protect the reverse flow of the current from a charging point/on- board charger. The Auxiliary Power System (APS) (105) is configured to convert High Voltage (HV) current to Low Voltage (LV) current according to the output received from the Battery Management System (BMS) (102).

[0014] In a more preferred embodiment of the invention, the battery pack (101 ), the Battery Management System (BMS) (102), the drivetrain unit (103), Discharge Protection Switch (DPS) (104), the Auxiliary Power System (APS) (105) are interconnected via a plurality of bus bars (106).

[0015] In a still preferred embodiment of the invention, the assembly is devoid of long wires or cables for interconnection of components of the power pack assembly.

[0016] In an additional embodiment of the invention, the battery pack (101 ) may comprises a cooling plate (107) mounted on a front and a back side of the battery pack (101 ).

[0017] In a preferred embodiment of the invention, the assembly is configured to be implemented within a 2-wheeler or 3 wheeler electric vehicle.

BRIEF DESCRIPTION OF THE DRAWINGS

[0018] FIG. 1 represents a block-diagram of an electronic packaging of battery and high voltage and high current power electronics (HV/HC) components inside using several long wires in a conventional electric vehicle. [0019] FIG. 2 showing a schematic representation of a compact power pack assembly to be mounted in an electric vehicle according to an embodiment of the present invention.

[0020] FIG. 3 showing an isometric side-view of the compact power pack assembly according to an embodiment of the present invention.

[0021 ] FIG. 4 showing an exploded view of the compact power pack assembly according to an embodiment of the present invention.

[0022] FIG. 5 showing a separate exploded view of an arrangement of a plurality of bus bars according to an embodiment of the present invention.

[0023] FIG. 6 showing an exploded view of an arrangement of bus bars on a compact power pack assembly according to an embodiment of the present invention.

[0024] FIG. 7 showing a block diagram representing current flow within the power pack assembly according to an embodiment of the present invention.

DESCRIPTION

[0025] Detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention 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.

[0026] FIG. 1 shows a block diagram of conventional packaging of high voltage electronic components such as Battery Management System (BMS), Cell Array, Discharge Protection Switch (DPS), Motor controller or Drive Train Unit (DTU), Auxiliary Power System (APS), etc., using several number of wires inside an electric vehicle. The use of long wires makes the packaging complex and time-consuming especially for those components, which are in contact with more than two components. For example, each of Drive Train Unit (DTU) 103 and Auxiliary Power System (APS) 105 are needed to be in electrical contact with both Battery Management System (BMS) and cell array, which in turn also needs to be in connection with each other. Thus, such arrangement needs a lot of time and effort during packaging to ensure each wire are not tangled or loose and it also makes hard to spot a defective wire at time of repairing or testing.

[0027] FIG.2 represents a block diagram showing the arrangement of all the HV/HC components in a compact power pack assembly 100 according to a preferred embodiment of the invention. The HV/HC components include a battery pack 101 , a Battery Management System (BMS) 102, a Drive Train Unit (DTU) 103, Digital Protection Switch (DPS) 104, Auxiliary power System (APS) 105. All these components are interconnected via a plurality of bus bars 106 to form a compact assembly. This will be clearer from the following discussion of FIG. 3.

[0028] FIG. 3 shows an isometric side-view of the compact power pack assembly according to an embodiment of the present invention. The battery pack 101 comprises a first cell array 101 a and a second cell array 101 b. Each of the cell arrays comprising a multiple single battery cells which are electrically and mechanically connected in series in a row and arranged in parallel in a closely packed configuration. The first cell array 101 a is mounted on the second cell array 101 b, or vice versa to form a compact battery pack 101 . Each of the cell arrays stores electrical power for powering the motor and other electrical loads of the vehicle. The battery cells must be reliably connected to achieve the voltage and power levels necessary to power these electrical loads. In a preferred embodiment of the invention, the cells are cylindrical and are arranged in a predefined non-overlapping arrangement. For example, the battery pack 101 suitable to be used with the compact power-pack assembly 100 is disclosed in patent application No IN 202221013223 dated 11 ^th March, 2022 for “A power pack with an integrated active thermal management system for an electric vehicle” filed herewith, the disclosure of which is herein incorporated by reference.

[0029] The Battery Management System (BMS) 102 is connected to the top of the battery pack 101 . In an embodiment of the invention, the Battery Management System (BMS) 102 is configured to manage the current input and output of the battery pack 101. In other words, Battery Management System (BMS) 102 detects battery status in real-time and uses the information to control the functionality of the electric vehicle. Additionally, Battery Management System (BMS) 102 is configured to receive two input lines from an On-board Charger (OBC) of the vehicle. In a preferred embodiment of the invention, a single Battery Management System (BMS) 102 is used to control charging and discharge of the first cell array 101 a and the second cell array 101 b. There may be more than two cell arrays which are controlled by single Battery Management System (BMS).

[0030] The drivetrain unit (DTU) 103 is mounted on one side of the cell array. The Drive Train Unit (DTU) 103 is adapted to control and send signals to an electric motor (not shown) according to the output received from the Battery Management System (BMS) 102. The electric motor is disposed in the electric vehicle external to power pack assembly 100. The Drive T rain Unit (DTU) 103 of the electric vehicle can include one or more inverter modules.

[0031 ] The Discharge Protection Switch (DPS) 104 is connected to top of the Drive Train Unit (DTU) 103 and is fitted on one line with an on-board charger (OBC) (not shown) of the vehicle. The Battery Management System (BMS) 102 is configured to receive two input lines from the On-board Charger (OBC). The Discharge Protection Switch (DPS) 104 protects the reverse flow of the current from the charging point.

[0032] The Auxiliary Power System (APS) 105 is adapted to convert High Voltage (HV) direct current to Low Voltage (LV) direct current according to the output received from the Battery Management System (BMS) 102.

[0033] The assembly further comprises a plurality of bus bars 106. In a preferred embodiment of the invention, the battery pack 101 , the Battery Management System (BMS) 102, the drivetrain unit (DTU) 103, the Discharge Protection Switch (DPS) 104, the Auxiliary Power System (APS) 105 are interconnected via a plurality of bus bars 106 enabling closely-pack arrangement of HV/HC electric components. In other words, as all the electronic components are in a closely packed configuration they can be electrically connected via a plurality of shorter bus bars 106. Thus, eliminating the need of long thick wires/cables while reducing weight, cost, copper-based losses, and EMI/EMC issues associated with the use of long wires/cables.

[0034] The assembly 100 has two types of currents following inside the power Pack i.e., Alternate current (AC) and Direct Current (DC). That is, Battery Pack 101 is the source of the Direct Current & Voltage, while Drive Train Unit (DTU) 103 is the source of Alternating Current and Voltage. The Drive Train Unit (DTU) 103 takes Direct Current & Voltage as input from the Battery pack 101 and converts it into Alternating Current and Voltage which is used to drive the motor of the Vehicle. Accordingly, bus bars 106 include AC carrying bus bars and DC carrying bus bars. As it is known in the art, the AC carrying bus bars and DC carrying bus bars must not cross each other to limit the emissions of electromagnetic waves below automotive standards, as higher emissions may cause the unwanted effects. In a preferred embodiment of the invention, a plurality of bus bars 106 are arranged in a manner that two types of bus bars do not cross each other. This arrangement ensures lower emission and eliminates the requirement of any extra devices to control the emission.

[0035] FIG. 7 shows a block diagram representing current flow within the power pack assembly 100. The battery pack 101 has direct voltage and current received from the external charging point (not shown). This direct voltage and current is provided via bus bars to the Drive Train Unit (DTU) 103 and the Auxiliary Power System (APS) 105 from which it is transferred to peripheral devices as per need. For example, Auxiliary Power System (APS) 105 takes high voltage DC from the battery Pack 101 Via bus bars 106 and converts it to low voltage DC which goes external to power pack assembly 100 to the various LV DC operated electrical loads, may or may not using wires. Similarly, the Drive Train Unit (DTU) 103 receives DC voltage from the battery pack and converts the same into AC voltage that is then used for driving the motor of the Vehicle. In a preferred embodiment of the invention, the bus bars 106 connecting the battery pack 10 with the Auxiliary Power System (APS) 105 and Drive Train Unit (DTU) 103 are DC carrying bus bars, while the bus bars 106 connecting Drive Train Unit (DTU) 103 with motor are AC carrying bus bars.

[0036] The power pack further comprises a cooling plate 107 mounted on a front and a back side of the battery pack 101 . The cooling plate has a spiral passage formed throughout its surface area for directing coolant received from inlet 107a toward outlet 107b, while receiving heat from the end terminal of each cell of first cell array 101 a and the second cell array 101 b. In a preferred embodiment of the invention, each of the first cell array 101 and the second first cell array 101 b comprise a cooling plate 107 adapted to extract heat from at least one end terminal of the cell array. [0037] FIG. 5 shows a separate view of the arrangement of bus bars according to an embodiment of the present invention for easier understanding. FIG. 6 shows an exploded view of the arrangement of a plurality of short bus bars 106 in a compact power pack assembly according to an embodiment of the present invention. The bus bars 106 are custom-designed with consideration of the arrangement of the HV/HC components in the power pack assembly. The bus bars are light-weight. In a more preferred embodiment of the invention, the bus bars are made of copper. As all the components are closely packed and long wirings are replaced with lightweight busbars which transmit current from one component to another with lesser copper losses compared to the thick wires. Arrangement of HV bus-bars and high switching devices in a single enclosure acts as a faraday cage to suppress the issues related to EMI/EMC. This in turn reduces the weight of the vehicle providing it a better range.

[0038] The bus bars 106 includes high voltage bus bars and low voltage bus bars which are arranged in a manner that reduces the EMI/EMC issues which generally happens due to longer wire length. Additionally, this benefitted the vehicle in the following manner:

Reduces the complexity of the Electronic packaging

Decreases the need for soldering of wire leading to the simplified assembly process reduces the weight of the vehicle by eliminating the use of long thick wires which helps in increasing the range.

Reduce the copper losses and thereby working temperature of the internal components leading to the increasing the efficiency.

[0039] The power pack further comprises a ferrite core adapted to reduce the EMI/EMC issues. As the smaller bus bars are used, the length of the ferrite core is also reduced which help in the overall reduction in weight & size of the power pack.

[0040] In a more preferred embodiment of the invention, bus bars 106 are custom- designed light-weight and short bus bars that make the powertrain compact, weight savvy, space-savvy, cheap to manufacture and handle. Additionally, because of the light weight power train, the range and mileage of the vehicle are increased. Each bus bars 106 have differing length and weight in determined consideration of the arrangement of the components it is dealing with. In a preferred embodiment of the invention, the bus bar 106 has, but not limited thereto, a rectangular strip like structure. In another embodiment of the invention, the bus bar 106 has C shape. In a preferred embodiment of the invention, each of the bus bars 106 has differing height, width and length. In a still another embodiment of the invention, total of 16 to 18 bus bars is used in a compact power assembly 100.

[0041 ] In a more preferred embodiment of the invention, the power-pack assembly 100 forms a housing or enclosure for the HV/HC electronic component of the vehicle. This housing is made of a material having dust and waterproof property having an IP67 rating. This eliminates the need for additional components that are required to protect each component from the adverse effect of water and dust. This further reduces the weight and cost of the vehicle which leads to increased power density, mileage, and range of the vehicle.

[0042] The power-pack assembly 100 may be implemented in electric vehicles having two or more wheels, more preferably two wheels. In an alternative embodiment, the power-pack assembly 100 can be implemented within any of battery-powered vehicles, hydrogen-powered vehicles, and fuel-cell-powered vehicles.

[0043] In the description of the present invention, it should be noted that the terms HV represents high Voltage, preferably voltage greater than 60 Volts and LV represents low voltage, preferably voltage below 60 volts.

[0044] In the description of the present invention, it should be noted that the terms "side", "front", “top”, “bottom”, "back" and the like indicate the directions or positional relationships based on the directions or positional relationships shown in the drawings, or the directions or positional relationships that the products of the present invention are conventionally placed when used, and are only for the convenience of describing the present invention and simplifying the description, but do not indicate or imply that the device or element to be referred to must have a specific direction, be constructed and operated in a specific direction, and thus, should not be construed as limiting the present invention. [0045] 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.

[0046] 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 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.