in South Korea’s BASTRO Power Station is very interesting. It was Koreans who took apart the Hyundai Ioniq 5 battery system and showed them at the Pack level. But this video can't be downloaded, I will do some sorting according to my interpretation, mainly based on the electrical design.
Hyundai deliberately blackened all the high-voltage copper bars and connecting wires during the publicity process, which looked more beautiful; when the actual disassembly was orange cables, the overall engineering beauty of the battery pack was reduced.
Figure 1 Ioniq 5 battery system design
Note: I want to say seriously that the current domestic competition of fast charging has entered a fierce situation, that is, as disclosed by the honeycomb Roadmap is highly probable that Chinese companies enter the competition schedule around fast charging cores. As electric vehicles line up on the highway for charging, this kind of fast charging can solve problems immediately and is an important way to show muscles.
Figure 2 has a great influence on the high-voltage 800V electrical design
1. Ioniq5 battery design
EMP platform configuration method, we can list the power of a single module It is 2.42 kWh, so there are currently 3 versions that can be configured:
1) 58kWh This is a basic configuration version, 24 modules, 288 cells
2) 72.6kWh (450kg, 161Wh/kg) This is 30 modules configuration, 360 cells
Figure 3 Two modules are added
3) 77.4kWh, of which 77.4kWh, 384 cells
from EMP From the perspective of design, we still use the idea of modular design; from the current design trend,EMP may have a quick switch-switch from this standard module method to a larger module design.
I think there is an essential question in the design of electric vehicles. Do you want PDU? What is
PDU, in fact, is to help the battery system to split the line. If only one BDU is designed and the battery is used as an output to manage all high-voltage electrical sources, then you have to split the line inside the battery. You do not have this premise. PDU must always exist. Drying out the PDU is at the cost of internal wiring of the battery system.
As shown in the figure below, this BDU can see:
- A pair of positive and negative poles of the high-voltage connector output
- A pair of positive and negative poles of the high-voltage connection are sent to the front end
- is connected to the positive and negative terminals of the direct voltage terminal of the battery Negative
- small current and high voltage connection of auxiliary power end
Note: Because this car is designed with a 400V to 800V design, the fast charging contactor is all integrated into the electric drive system, so the PDU here is disassembled It is divided into two parts, the battery system is one part, and the electric drive system is the other part
Figure 4 Do you need PDU for the power distribution box?
In this battery pack, there is no PDU, so the front output of the BDU needs to be pulled to the front end through the high-voltage round wire output (in order to fix the round wire well, a supporting is also made. Foam), due to the relatively high voltage of 800V, an intermediate fuse design is used here (800V may require Pyrofuse to cut).
Figure 5 The output before the fuse box in 800V Pack
2. BMS and CMU
are in this,The same as the public approach-800V's biggest challenge to the design of BMS is whether it can be made centralized, that is to say, can the 192 series of acquisition channels in the current EMP be processed together? From the existing 800V design scheme:
- Taycan is completely distributed, try to complete the sampling in the module
- EMP is semi-distributed, and Koreans have always used temperature collection and voltage collection in the design Separate them with cables and connect them to the distributed collection CMU in the middle
As shown in the figure below, in this package, the most unsightly thing is these voltage cables and temperature cables, from each module Connect them and aggregate them to the distributed CMU in the middle.
Figure 6 Module sampling voltage and temperature two cables
I estimate that the CMU layout of the following PPE platform is probably similar, and all 800V CMUs should be built in It's a bit difficult together.
Figure 7 The placement of the CMU of EMP and MEB
The design of this BMU also adopts the high and low voltage separation mode. It is likely to guess that the high voltage acquisition circuit is integrated in the above BDU. , So that the BMU can be made so small, it can be seen from the outside that the BMU does not have an orange high-voltage line input.
Figure 8 The design of the BMU of this 800V battery system
Summary: I think the design of the 800V battery system looks simple, but if you do from 2C to 4C, in fact It is high voltage and high current, there are still many places to optimize. At present, all domestic high-end brands are doing design, from 2C to 4C vertically.This is an extreme arms race! You guys have fun, I'll just check it out.
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