WO2022149053A1

WO2022149053A1 - A system for enabling modular and scalable architecture for a battery-operated vehicle

Info

Publication number: WO2022149053A1
Application number: PCT/IB2022/050016
Authority: WO
Inventors: S. B. Pandit (Ravi); Tejas Krishna Kshatriya
Original assignee: Kpit Technologies Limited
Priority date: 2021-01-05
Filing date: 2022-01-03
Publication date: 2022-07-14

Abstract

Present invention relates to a system (100) for enabling modular and scalable architecture for converting a battery-operated vehicle into a fuel cell electric vehicle and vice versa without any changes to the vehicle architecture. The system (100) comprises an interface (102) communicatively coupled, at one end, with a vehicle sub-system (104), and, at the other end, with a flexible energy storage sub-system (106) so as to isolate the vehicle sub-system (104) from the flexible energy storage sub-system (106). The interface (102) comprises any or a combination of a software communication interface (102-1), an electrical interface (102-2), and a mechanical interface (102-3).

Description

A SYSTEM FOR ENABLING MODULAR AND SCALABLE ARCHITECTURE FOR A BATTERY-OPERATED VEHICLE

FIELD OF THE INVENTION

[0001] The present invention relates to a system architecture for vehicles and, in particular relates to a modular and scalable system architecture and method suitable for any type of hybrid and battery-operated vehicles.

BACKGROUND OF THE INVENTION

[0002] Background description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.

[0003] Currently, the automotive landscape has been evolving with the changing demands of the users, the environmental concerns, the fuel supply and demands, the automotive industry regulations, etc. With these changing requirements, the conventional IC engines have been replaced with hybrid electric vehicles/ electric vehicles/ and fuel cell hybrid electric vehicles. Due to the environmental concerns, the hybrid/electric vehicles are in demand, while fuel cell vehicles are emerging in the market as the research progresses. [0004] The hybrid/electric vehicles are battery operated vehicles that are economical and environment friendly. The fuel cell vehicles too are battery operated vehicles and are economic and environmentally friendly. Both these vehicles use one or more electric motors for propulsion. Though currently, hybrid/electric vehicles are in demand, with the growing research and simpler solutions for hydrogen generation and storage, fuel cell vehicles will be in demand in the future. Both these vehicles being battery operated, economical, and good for the environment, will co-exist in the near future. Currently, the vehicle system architecture is designed based on the type of the battery-operated vehicle - whether it is hybrid vehicle, an electric vehicle or a fuel cell vehicle. The existing system architectures of the battery- operated vehicles are tightly integrated, cannot be scaled and are very specific to the type of the battery-operated vehicle. Thus, there is a need for a vehicle system architecture which is modular and scalable and can be used for any type of battery-operated vehicle. There is a need for a modular and scalable system architecture, which is not tightly integrated and which can be easily used for any type of battery operated vehicle with minimal modifications. [0005] Additionally, based on the supply and availability of hydrogen, there would be a need to use either a hybrid/electric vehicle or convert an existing hybrid/electric vehicle into a fuel cell vehicle. Due to the evolving nature of hydrogen supply, storage and availability, there may be a need to convert an existing fuel cell vehicle into a hybrid/electric vehicle. Converting existing hybrid/electric vehicle into fuel cell vehicles, or vice versa is not convenient, feasible, and is very time-consuming. In the existing battery-operated vehicles/fuel cell vehicles, the vehicle Electronic Control Units (ECUs) and the power train ECUs are tightly integrated with the storage systems. The electrical interfaces are such that all the systems are tightly integrated with the wiring harness. Additionally, the mechanical systems of the existing hybrid/electric vehicles and the fuel cell vehicles are designed considering either the battery pack or the fuel cell systems. The same mechanical systems cannot accommodate the energy storage systems interchangeably. Thus, with the existing architecture and design of the hybrid/electric vehicles and the fuel cell vehicles, they are not swappable and cannot be converted easily without significant modifications to the vehicle architecture.

[0006] There is a need for a modular, scalable, and swappable architecture which can be used for any type of battery-operated vehicle with minimal modifications. There is a need for a modular, scalable and swappable system architecture and method for battery-operated vehicles, wherein the entire vehicle structure remains unchanged, except the battery and the storage module which is reconfigured as per the requirement. There is a need for a battery- operated vehicle system architecture and method, where the architecture is modular, scalable, and swappable, with minimum changes to any of the existing vehicle structures.

[0007] There is, therefore, a need in the art to develop a system for enabling modular and scalable architecture for a battery-operated vehicle, which results in a quick and easy method for converting any modular and scalable architecture for a battery-operated vehicle into a fuel cell vehicle, and vice versa.

OBJECTS OF THE PRESENT DISCLOSURE

[0008] Some of the objects of the present disclosure, which at least one embodiment herein satisfies are as listed herein below.

[0009] Accordingly, it is an object of the present invention to provide an efficient solution for modular and scalable system architecture for BEV and FCEV. [0010] It is another object of the present invention to provide a modular and scalable mechanical interface, communication interface, and electrical interface that are not tightly integrated into the system and can be easily customized.

[0011] It is another object of the present invention to provide a modular and scalable software interface to seamlessly enable and disable BEV and FCEV functions as per the requirement.

[0012] It is another object of the present invention to provide a customizable and flexible solution that can switch between mechanical, electrical, and communication interfaces.

[0013] It is another object of the present invention to provide an effective mechanism for converting BEV into FCEV and vice versa without any modification to the architecture, thereby reducing the time and efforts of conversion.

[0014] It is another object of the present invention to provide a swappable system architecture and method for converting an existing BEV into a FCEV and vice versa

SUMMARY

[0015] The present invention relates to a system architecture for vehicles and, in particular relates to a modular and scalable system architecture and method suitable for any type of hybrid and battery-operated vehicles.

[0016] According to an aspect of the present disclosure, a system for enabling modular and scalable architecture for a battery-operated vehicle is disclosed. The system comprises an interface, which is communicatively coupled with a vehicle sub- system and a flexible energy storage sub-system on either side, such that the vehicle sub-system is isolated from the flexible energy storage sub-system. The interface comprises any or a combination of a software communication interface, an electrical interface, and a mechanical interface.

[0017] According to another aspect of the present disclosure, the software communication interface is in direct communication with the energy storage sub-system through a flexible vehicle communication network. The flexible vehicle communication network is dedicated to facilitating communication of one or more parameters between an Electric Power Train (EPT) and the energy storage sub-system. The parameters are selected from any or a combination of voltage attributes, current attributes, power attributes, energy attributes, temperature attributes, fault-based attributes, and service data based attributes. [0018] According to an aspect of the present disclosure, the electrical interface is in direct communication with the energy storage sub-system through an adaptable wire and connector network. The network is dedicated to facilitating communication of one or more parameters between an electric drive system and the energy storage sub-system. The parameters are selected from any or a combination of power connector pin details, control signal specifications, a connector for control signals, color codes for wires, and design guidelines for cable sizes.

[0019] According to an aspect of the present disclosure, the mechanical interface interconnects with the energy storage sub-system through a plurality of modular mechanical fittings. The modular mechanical fittings are dedicated to facilitating communication of parameters between vehicle body, vehicle chassis, and the energy storage sub-system. The parameters are being selected from any or a combination of rooftop railing on the bus, crate/modular dimensions, and mechanical interconnections brackets/mountings.

[0020] According to an aspect of the present disclosure, the vehicle sub-system comprises one or more of a drive unit, a cluster unit, a vehicle control unit, a charge control unit, a diagnostics unit, a power steering unit, a brake unit, a suspension unit, lighting and ITS unit, an Electric Power Train (EPT), an electric drive system, a vehicle body, and a vehicle chassis.

[0021] According to an aspect of the present disclosure, the flexible energy storage sub-system comprises one or more of a battery, one or more of a storage tank, one or more of a fuel cell.

[0022] According to an aspect of the present disclosure, the battery-operated vehicle comprises any of a battery electric vehicle (BEV) and fuel cell electric vehicle (FCEV). The interface is modular and enables the conversion of a BEV into FCEV and vice versa, without any changes in the architecture.

[0023] According to an aspect of the present disclosure, the flexible energy storage sub-system comprises of battery packs that are mounted onto the BEV using respective mounting brackets, where each of the battery packs is coupled to the vehicle body through a mechanical interface at predefined mounting points.

[0024] According to an aspect of the present disclosure, the battery packs are coupled to HVAC through a cooling interface using a hydraulic hose connector.

[0025] According to an aspect of the present disclosure, the flexible energy storage sub-system comprises a combination of the battery pack(s) and fuel cell stack(s) battery packs that are arranged onto the FCEV. Further, the flexible energy storage sub-system comprises a fuel cell cooling sub-system, one or more hydrogen cylinders, mounting brackets for respective hydrogen cylinders, and a balance of plant fuel cells, where using the interface, one or more battery packs are replaceable by corresponding hydrogen cylinders and/or fuel cell stacks for FCEV conversion without any change in the architecture.

[0026] According to an aspect of the present disclosure, the one or more hydrogen cylinders and the mounting brackets for respective hydrogen cylinders form part of a hydrogen cylinder sub- system that further comprises any or a combination of receptacle, hydrogen piping, sensor(s), safety protection device(s), wiring harness, and control system. [0027] The hydrogen cylinder sub- system is coupled with a mechanical interface to enable the use of hydrogen compatible piping and connectors to facilitate coupling between the fuel cell stack(s) with one or more hydrogen cylinders.

[0028] According to an aspect of the present disclosure, the interface enables the transition of energy mode of the energy storage sub-system from pure battery based mode to fuel-cell based mode. Further, the interface enables change in configuration of the energy storage sub-system through an Electronic Control Unit (ECU).

[0029] Various objects, features, aspects and advantages of the present disclosure will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like features. [0030] Within the scope of this application it is expressly envisaged that the various aspects, embodiments, examples and alternatives set out in the preceding paragraphs, in the claims and/or in the following description and drawings, and in particular the individual features thereof, may be taken independently or in any combination. Features described in connection with one embodiment are applicable to all embodiments unless such features are incompatible.

BRIEF DESCRIPTION OF DRAWINGS

[0031] The accompanying drawings are included to provide a further understanding of the present disclosure, and are incorporated in and constitute a part of this specification. The drawings illustrate exemplary embodiments of the present disclosure and, together with the description, serve to explain the principles of the present disclosure. The diagrams are for illustration only, which thus is not a limitation of the present disclosure.

[0032] FIG. 1 illustrates the block diagram for the modular and scalable system architecture and method, in accordance with an embodiment of the present disclosure.

[0033] FIG. 2 illustrates a battery pack/energy storage arrangement for a battery electric vehicle, in accordance with an embodiment of the present disclosure. [0034] FIG. 3 illustrates a battery pack/energy storage arrangement for fuel cell electric vehicles, in accordance with an embodiment of the present disclosure.

[0035] FIG. 4 illustrates the electrical interface in BEV architecture, in accordance with an embodiment of the present disclosure.

[0036] FIG. 5 illustrates a swappable design for BEV and FCEV, in accordance with an embodiment of the present disclosure.

DETAILED DESCRIPTION

[0037] The following is a detailed description of embodiments of the disclosure depicted in the accompanying drawings. The embodiments are in such detail as to clearly communicate the disclosure. However, the amount of detail offered is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosure as defined by the appended claims.

[0038] In the following description, numerous specific details are set forth in order to provide a thorough understanding of embodiments of the present invention. It will be apparent to one skilled in the art that embodiments of the present invention may be practiced without some of these specific details.

[0039] Embodiments of the present invention include various steps, which will be described below. The steps may be performed by hardware components or may be embodied in machine-executable instructions, which may be used to cause a general-purpose or special- purpose processor programmed with the instructions to perform the steps. Alternatively, steps may be performed by a combination of hardware, software, and firmware and/or by human operators.

[0040] Various methods described herein may be practiced by combining one or more machine-readable storage media containing the code according to the present invention with appropriate standard computer hardware to execute the code contained therein. An apparatus for practicing various embodiments of the present invention may involve one or more computers (or one or more processors within a single computer) and storage systems containing or having network access to computer program(s) coded in accordance with various methods described herein, and the method steps of the invention could be accomplished by modules, routines, subroutines, or subparts of a computer program product. [0041] If the specification states a component or feature “may”, “can”, “could”, or

“might” be included or have a characteristic, that particular component or feature is not required to be included or have the characteristic.

[0042] As used in the description herein and throughout the claims that follow, the meaning of “a,” “an,” and “the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise.

[0043] Exemplary embodiments will now be described more fully hereinafter with reference to the accompanying drawings, in which exemplary embodiments are shown. These exemplary embodiments are provided only for illustrative purposes and so that this disclosure will be thorough and complete and will fully convey the scope of the invention to those of ordinary skill in the art. The invention disclosed may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Various modifications will be readily apparent to persons skilled in the art. The general principles defined herein may be applied to other embodiments and applications without departing from the spirit and scope of the invention. Moreover, all statements herein reciting embodiments of the invention, as well as specific examples thereof, are intended to encompass both structural and functional equivalents thereof. Additionally, it is intended that such equivalents include both currently known equivalents as well as equivalents developed in the future (i.e., any elements developed that perform the same function, regardless of structure). Also, the terminology and phraseology used is for the purpose of describing exemplary embodiments and should not be considered limiting. Thus, the present invention is to be accorded the widest scope encompassing numerous alternatives, modifications and equivalents consistent with the principles and features disclosed. For purpose of clarity, details relating to technical material that is known in the technical fields related to the invention have not been described in detail so as not to unnecessarily obscure the present invention.

[0044] Thus, for example, it will be appreciated by those of ordinary skill in the art that the diagrams, schematics, illustrations, and the like represent conceptual views or processes illustrating systems and methods embodying this invention. The functions of the various elements shown in the figures may be provided through the use of dedicated hardware as well as hardware capable of executing associated software. Similarly, any switches shown in the figures are conceptual only. Their function may be carried out through the operation of program logic, through dedicated logic, through the interaction of program control and dedicated logic, or even manually, the particular technique being selectable by the entity implementing this invention. Those of ordinary skill in the art further understand that the exemplary hardware, software, processes, methods, and/or operating systems described herein are for illustrative purposes and, thus, are not intended to be limited to any particular named element.

[0045] Systems depicted in some of the figures may be provided in various configurations. In some embodiments, the systems may be configured as a distributed system where one or more components of the system are distributed across one or more networks in a cloud computing system.

[0046] Each of the appended claims defines a separate invention, which for infringement purposes is recognized as including equivalents to the various elements or limitations specified in the claims. Depending on the context, all references below to the "invention" may in some cases refer to certain specific embodiments only. In other cases, it will be recognized that references to the "invention" will refer to subject matter recited in one or more, but not necessarily all, of the claims.

[0047] All methods described herein may be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided with respect to certain embodiments herein is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention otherwise claimed. No language in the specification should be construed as indicating any non-claimed element essential to the practice of the invention.

[0048] Various terms as used herein are shown below. To the extent a term used in a claim is not defined below, it should be given the broadest definition persons in the pertinent art have given that term as reflected in printed publications and issued patents at the time of filing.

[0049] The present invention relates to a system architecture for vehicles and, in particular relates to a modular and scalable system architecture and method suitable for any type of hybrid and battery-operated vehicles.

[0050] According to an aspect of the present disclosure, a system for enabling modular and scalable architecture for a battery-operated vehicle is disclosed. The system comprises an interface, which is communicatively coupled with a vehicle sub- system and a flexible energy storage sub-system on either side, such that the vehicle sub-system is isolated from the flexible energy storage sub-system. The interface comprises any or a combination of a software communication interface, an electrical interface, and a mechanical interface.

[0051] According to another aspect of the present disclosure, the software communication interface communicates with the flexible energy storage sub- system through a flexible vehicle communication network. The flexible vehicle communication network is dedicated to facilitate communication of one or more parameters between an Electric Power Train (EPT) and the energy storage sub-system. The parameters being selected from any or a combination of voltage attributes, current attributes, power attributes energy attributes, temperature attributes, fault-based attributes, and service data based attributes.

[0052] According to an aspect of the present disclosure, the electrical interface is in direct communication with the energy storage sub-system through an adaptable wire and connector network. The network is dedicated to facilitate communication of one or more parameters between an electric drive system and the energy storage sub-system. The parameters being selected from any or a combination of power connector pin details, control signal specifications, connector for control signals, color codes for wires, and design guidelines for cable sizes.

[0053] According to an aspect of the present disclosure, the mechanical interface interconnects with the energy storage sub-system through a plurality of modular mechanical fittings. The modular mechanical fittings are dedicated to facilitate communication of parameters between vehicle body, vehicle chassis and the energy storage sub-system. The parameters are being selected from any or a combination of roof top railing on the bus, crate/modular dimensions, and mechanical interconnections brackets/mountings.

[0054] According to an aspect of the present disclosure, the vehicle sub-system comprises one or more of a drive unit, a cluster unit, a vehicle control unit, a charge control unit, a diagnostics unit, a power steering unit, a brake unit, a suspension unit, a lighting and ITS unit, an electric power train (EPT), an electric drive system, a vehicle body, and a vehicle chassis.

[0055] According to an aspect of the present disclosure, the flexible energy storage sub-system comprises one or more of a battery, one or more of a storage tank, and one or more of a fuel cell.

[0056] According to an aspect of the present disclosure, the battery-operated vehicle comprises any of a battery electric vehicle (BEV) and fuel cell electric vehicle (FCEV). The interface is modular and enables conversion of a BEV into FCEV and vice versa, without any changes in the architecture. [0057] According to an aspect of the present disclosure, the flexible energy storage sub-system comprises of battery packs that are mounted onto the BEV using respective mounting brackets, where each of the battery packs is coupled to the vehicle body through a mechanical interface at predefined mounting points.

[0058] According to an aspect of the present disclosure, the battery packs are coupled to HVAC through a cooling interface using a hydraulic hose connector.

[0059] According to an aspect of the present disclosure, the flexible energy storage sub-system comprises a combination of battery pack(s) and fuel cell stack(s) battery packs that are arranged onto the FCEV. Further, the flexible energy storage sub-system comprises a fuel cell cooling sub-system, one or more hydrogen cylinders, mounting brackets for respective hydrogen cylinders, and balance of plant fuel cell, where using the interface, one or more battery packs are replaceable by corresponding hydrogen cylinders and/or fuel cell stacks for FCEV conversion without any change in the architecture.

[0060] According to an aspect of the present disclosure, the one or more hydrogen cylinders and the mounting brackets for respective hydrogen cylinders form part of a hydrogen cylinder sub- system that further comprises any or a combination of receptacle, hydrogen piping, sensor(s), safety protection device(s), wiring harness, and control system. The hydrogen cylinder sub-system is coupled with a mechanical interface to enable use of hydrogen compatible piping and connectors to facilitate coupling between the fuel cell stack(s) with the one or more hydrogen cylinders.

[0061] According to an aspect of the present disclosure, the interface enables transition of energy mode of the energy storage sub-system from pure battery based mode to fuel-cell based mode. Further, the interface enables change in configuration of the energy storage sub-system through an Electronic Control Unit (ECU).

[0062] FIG. lillustrates the block diagram for the modular and scalable system architecture and method, in accordance with an embodiment of the present disclosure.

[0063] According to an embodiment, a system 100 enables modular and scalable architecture for a battery-operated vehicle. The system 100 comprises an interface 102, which is communicatively coupled with a vehicle sub-system 104 and a flexible energy storage sub system 106 on either side, such that the vehicle sub- system 104 is isolated from the flexible energy storage sub-system 106. The interface 102 comprises any or a combination of a software communication interface 102-1, an electrical interface 102-2, and a mechanical interface 102-3. [0064] In an embodiment, the vehicle sub- system 104 comprises of, but is not limited to, a drive unit 104-1, a cluster unit 104-2, a vehicle control unit 104-3, a charge control unit 104-4, a diagnostics unit 104-5, a power steering unit 104-6, a brake unit 104-7, a suspension unit 104-8, a lighting and ITS unit 104-9, an electric power train 104-10, an electric drive system/aux 104-11, a vehicle body 104-12 and a vehicle chassis 104-13. The energy storage system 106 comprises of, but not limited to, batteries, storage tanks, fuel cells, hydrogen containers, etc. as per the requirement of the vehicle.

[0065] In an embodiment, the software communication interface 102-1 is in direct communication with the flexible energy storage system 106 via a flexible vehicle communication network 108, where the vehicle communication network 108 can be CAN, automotive wifi, flexray, ethernet, LIN, and the like. The electrical interface 102-2 is in direct communication with the flexible energy storage system 106via an adaptable wire and connector network 110. The mechanical interface 102-3 interconnects with the flexible energy storage system 106 via modular mechanical fittings 112.

[0066] In an embodiment, the parameters, their data type/range and communication address is well defined at the flexible energy storage system 106 and at the EPT (electric power train) 104-10. For example, the parameters communicated between the electric power train EPT 104-10 and the flexible energy storage system 106 by the software communication interface 102-1 over the flexible vehicle communication network 108, include but are not limited to, Voltage_min, Voltage_max, Current_rated, Current_max, Power_rated, Power_max, Energy_total available, Energy_cumulative consumed, Energy_remaining, Energy_consumed, Tempt_min, Tempt_max, Faults, Service data/parameters. For example, parameters between the electric drive system 104-11 and the flexible energy storage system 106 that are governed/controlled/communicated by the electrical interface 102-2 through the adaptable wire and connectors network 110, include, but are not limited to, power connector pin details, control signal specifications, a connector for control signals, color codes for wires, design guidelines for cable sizes. For example, parameters between the vehicle body 104-12, the vehicle chassis 104-13 and the flexible energy storage system 106 that are govemed/controlled/communicated by the mechanical interface 112 through the modular mechanical fittings, include, but are not limited to, roof top railing on the bus, crate/modular dimensions (stackable), mechanical interconnections brackets/mounting points.

[0067] FIG. 2 illustrates a battery pack/energy storage arrangement for battery electric vehicle, in accordance with an embodiment of the present disclosure. [0068] In an embodiment, the battery pack/energy storage arrangement 200 includes a battery pack 202, and a battery pack mounting bracket 204. Further, depending upon the vehicle specifications and range requirement, the battery packs 202 are arranged on the electric vehicle as shown in FIG. 2. The number of battery packs 202 can be added depending on the energy requirement, each of the one or more battery packs 202 is coupled to HVAC through a cooling interface using a hydraulic hose connector. Thus, the system is known as a scalable vehicle energy requirement.

[0069] In another embodiment, the modularity of battery pack 202 requirement includes the battery packs 202 coupled with other subsystems via the interface 102 as shown in FIG. 1. The mechanical interface 102-3 is coupled with the vehicle body 104-11. The battery subsystem is coupled to the vehicle body 104-12at a certain mounting point which is common for BEV and FCEV. The mechanical interface 102-3 of the battery packs with the vehicle is through uniquely designed battery pack mounting bracket 204 as shown FIG. 2. Most of the complexities for an auxiliary component like wiring harness routing, cooling circuit routing and mounting is managed in bracket design, which ensures that there will be minimal changes required on vehicle body 104-12 for the battery pack 202 integration with the vehicle.

[0070] FIG. 3 illustrates a battery pack/energy storage arrangement for fuel cell electric vehicle, in accordance with an embodiment of the present disclosure.

[0071] In an embodiment, depending upon the vehicle specifications and range requirement, the battery pack 202, a fuel cell stack 306 and its balance of plant are arranged on fuel cell electric vehicle as shown in FIG. 3.

[0072] In an embodiment, energy storage arrangement for fuel cell electric vehicle

300 includes a fuel stack sub-system 302, a hydrogen cylinder subsystem 304, the fuel cell stacks 306, the battery pack 202, a fuel cell cooling system 308, a balance of plant fuel cell 310, a hydrogen cylinder mounting bracket 312, and hydrogen cylinders 314.

[0073] In an embodiment, the hydrogen cylinders with bracket 312, receptacle, hydrogen piping, sensors, and safety protection devices, wiring harness, control system are a preassembled unit. This unit is known as a “hydrogen cylinder subsystem 304”, which is coupled with other subsystems via the mechanical interface 102-2 and the electrical interface 102-3.

[0074] In an embodiment, the hydrogen compatible piping and connectors are configured to couple the fuel cell stack 306 with the hydrogen cylinder 314. Also, hydrogen cylinder subsystem 304 is coupled to the vehicle body 104-12 at specific mounting locations which are common for BEV and FCEV.

[0075] In another embodiment, a cooling Interface with HVAC includes a hydraulic quick fix hose connector for connecting the battery cooling outlet/inlet with HVAC cooling circuit. Whenever the battery packs 202 are removed/added into the system, cooling hoses, wiring harness, and connectors are removed/added along with the battery pack 202. In fact, the battery pack assembly is designed in such a way that the entire peripheral components like a cooling hose, wiring harness are pre-assembled with battery pack 202. Thus, a “battery pack subsystem” is formed. While vehicle integration, just plugs the wiring harness connectors and cooling hose connectors. Thus, a modular battery pack is achieved as a subsystem.

[0076] FIG. 4 illustrates the electrical interface in BEV architecture, in accordance with an embodiment of the present disclosure.

[0077] In an embodiment, the electrical interface 102-2 includes a Battery

Management System_A (BMS_A) 402-1, a Fuel Cell Management System_l (FCMS_1) 404-1, a Battery Management System_B (BMS_B) 402-2, a Fuel Cell Management System_2 (FCMS_2) 404-2, ECU_MS 406-1, EUC_PF 406-2, EUC_FC 406-3, a power distribution unit 408, a fast charger 410, an on board changer 412, motor controller 414, inverter 416, a motor 418, a steering pump 420, an air brake component 422, a 24V stock battery 424, and a vehicle electrical load 426.

[0078] In an embodiment, BEV architecture consists of the following important interfaces -ECUs for BEV logic management, BMS for battery management, Motor and Motor controller for delivering and controlling power to vehicle, Charging interface, Dashboard and Auxiliary load on vehicle (e.g., power steering, various lamps etc.)

[0079] In another embodiment, FCEV architecture contains mainly following components - ECUs for EV logic management, BMS (Battery management system) for battery management, Motor controller for delivering and controlling power to vehicle, Dashboard and Auxiliary load on vehicle (e.g., power steering, various lamps etc.), Fuel cell stack, Balance of Plant for fuel cell stack, ECU-FC for controlling fuel cell stack functionality. The FCEV architecture includes fuel cell stack 306 and BoP (Balance of Plant) in FCEV architecture. In FCEV architecture charger interface 412 is optional.

[0080] In an embodiment, modularity is achieved in the software interface 102-1 by using ECU-MS 406-1 and ECU-FC 406-3 which involves all the functionality and logic required for pure BEV mode as well as FCEV mode. For example, in case of BEV complete electric power train is controlled by Master ECU & Slave ECU. When BEV is planned to be converted to FCEV, then separate ECU FC gets added to the system which controls the FC system functionality & gives inputs to Master ECU for vehicle control and in absence of FC system Master ECU will take inputs from BEV system only and no additional hardware change is required. The FCEV mode can be enabled or disabled in software using an external configuration tool (CAN-based software). Further, many functions/logics can be independently enabled or disabled in software using an external configuration tool. In addition, many parameter values can be changed using an external configuration tool.

[0081] In another embodiment, scalability is achieved in the software interface 102-1 by using ECU-MS 406-1 as well as ECU-FC 406-3 which is configured from an external configuration tool to support multiple batteries or multiple fuel cells. Further, ECUs also can be configured to support multiple BOP systems. ECUs can be configured to support multiple motor controllers 414 or single motor controller of different power ratings as required. ECUs are configured to support various charging protocols in BEV mode.

[0082] In another embodiment, fuel cell stack systems include fuel cell stacks 306, stack manifold, stack, the balance of plant 310 components like air compressor, humidifier, DC-DC converter, sensors, controls systems and mounting brackets comes as a preassembled unit called as a “Fuel cell Stack Systems”. These fuel cell stack systems are coupled with other subsystems via the following interfaces: the mechanical interface, the cooling system interface, the electrical interface, and the software interface.

[0083] In an embodiment, the fuel cell stack systems are coupled with the mechanical interface 102-3 with the vehicle body. The hydrogen compatible piping and connectors are used to couple the fuel cell stack 306 with the hydrogen cylinder 314. The fuel cell subsystem302 is integrated into to vehicle at specific mounting locations.

[0084] In an embodiment, the fuel cell stack systems are coupled with the cooling system interface with HVAC. Hydraulic quick fix hose connector is used to connect air compressor and controller cooling outlet/inlet with HVAC cooling circuit.

[0085] In an embodiment, the fuel cell stack systems are coupled with the electrical interface 102-2, common control interface connectors are used to connect either battery pack of the fuel cell system. Common power interface connectors are used to connect either battery pack of the fuel cell.

[0086] In an embodiment, the fuel cell stack systems are coupled with the software interface 102-1, ECU and BMS are used to monitor and control the complete functionality of fuel cell stack system. The components connected are enabled or disabled from the configuration. The functions and logics are configurable and can be enabled or disabled as per the requirement. The following interface 102 functions as mainly required for proper working of the system in modular and scalable way: communication with other ECUs 406 in the system, interfacing with physical signals, communication with sensors and actuators, and BoP 310 monitoring and controlling.

[0087] In an embodiment, the energy storage system scalability of FCEV depends on the increasing power requirement of the vehicle, which increases the number of the fuel cell stack 306. As shown in FIG. 3, currently 4 stacks are configured into the subsystem. These stacks are connected in parallel with manifold for uniform reactant flow, which is connected in series electrically for electrical power output. Thus, multiple fuel cell stack is used together for the scalability of power generation. Also depending on vehicle range requirement, the number of cylinders are added into the subsystem.

[0088] FIG. 5 illustrates a swappable design for BEV and FCEV, in accordance with an embodiment of the present disclosure.

[0089] In an embodiment, in a fuel cell vehicle all the battery packs 202, except one battery pack 202a (which is required to support the fuel cell system) will be replaced with a fuel cell subsystem consisting of a fuel cell stack subsystem 302 and hydrogen cylinder subsystem 304. The Hydrogen cylinder mounting bracket 312 is designed in such a way that it has an identical interface (mounting point) with battery pack mounting bracket/vehicle body. Other complexities like hydrogen piping, different types of sensors, safety protection devices, wiring harnesses are managed in cylinder bracket design which provides hydrogen cylinder subsystem 304. All the components of the subsystem are preassembled on the production line and integrated into the vehicle as a subsystem. With this arrangement, the battery packs in the battery electric vehicle will be swapped with hydrogen cylinder 314 with no changes in the vehicle body for converting it to fuel cell electric vehicle.

[0090] Although this present invention has been described herein with respect to a number of specific illustrative embodiments, the foregoing description is intended to illustrate, rather than to limit the invention. Those skilled in the art will realize that many modifications of the illustrative embodiment could be made which would be operable. All such modifications, which are within the scope of the claims, are intended to be within the scope and of the present invention. ADVANTAGES OF THE PRESENT DISCLOSURE

[0091] The present disclosure provides an efficient solution for modular and scalable system architecture for BEV and FCEV.

[0092] The present disclosure provides a modular and scalable mechanical interface, communication interface, and electrical interface that are not tightly integrated into the system and can be easily customized. The present disclosure provides a modular and scalable software interface to seamlessly enable and disable BEV and FCEV functions as per the requirement.

[0093] The present disclosure provides a customizable and flexible solution that can switch between mechanical, electrical, and communication interfaces.

[0094] The present disclosure provides an effective mechanism for converting BEV into FCEV and vice versa without any modification to the architecture, thereby reducing the time and efforts of conversion.

[0095] The present disclosure provides a swappable system architecture and method for converting an existing BEV into a FCEV and vice versa.

Claims

We Claim:

1. A system (100) for enabling modular and scalable architecture for a battery-operated vehicle, said system (100) comprising an interface (102) communicatively coupled, at one end, with a vehicle sub-system (104), and, at the other end, with a flexible energy storage sub-system (106) so as to isolate the vehicle sub-system (104) from the flexible energy storage sub-system (106), said interface (102) comprising any or a combination of a software communication interface (102-1), an electrical interface (102-2), and a mechanical interface (102-3).

2. The system (100) as claimed in claim 1, wherein the software communication interface (102-1) communicates with the flexible energy storage sub- system (106) through a flexible vehicle communication network (108), said flexible vehicle communication network (108) facilitating communication of one or more parameters between an Electric Power Train (EPT) (104-10) and the flexible energy storage sub-system (106), said one or more parameters being selected from any or a combination of voltage attributes, current attributes, power attributes energy attributes, temperature attributes, fault-based attributes, and service data based attributes.

3. The system (100) as claimed in claim 1, wherein the electrical interface (102-2) communicates with the flexible energy storage sub-system (106) through an adaptable wire and connector network (110), said network facilitating communication of one or more parameters between an electric drive system (104-11) and the flexible energy storage sub system (106), said one or more parameters being selected from any or a combination of power connector pin details, control signal specifications, connector for control signals, color codes for wires, and design guidelines for cable sizes.

4. The system (100) as claimed in claim 1, wherein the mechanical interface (102-3) interconnects with the flexible energy storage sub-system (106) through a plurality of modular mechanical fittings (112), said fittings facilitating communication of one or more parameters between vehicle body (104-12), vehicle chassis (104-13) and the flexible energy storage sub-system (106), said one or more parameters being selected from any or a combination of roof top railing on the bus, crate/modular dimensions, and mechanical interconnections brackets/mountings .

5. The system (100) as claimed in claim 1, wherein the flexible energy storage sub system (106) comprises one or more of a battery, one or more of a storage tank and one or more of a fuel cell.

6. The system (100) as claimed in claim 1, wherein the battery-operated vehicle comprises any of a Battery Electric Vehicle (BEV) and Fuel Cell Electric Vehicle (FCEV), and wherein the interface (102) is modular and enables conversion of a BEV into FCEV and vice versa, without any changes in the architecture.

7. The system (100) as claimed in claim 7, wherein the flexible energy storage sub system (106) comprises of one or more battery packs (202) that are mounted onto the BEV using respective mounting brackets (204), and wherein each of the one or more battery packs is coupled to vehicle body through a mechanical interface (102-3) at predefined mounting points.

8. The system (100) as claimed in claim 7, wherein the flexible energy storage sub system (106) comprises a combination of battery pack(s) (202) and fuel cell stack(s) (306) battery packs that are arranged onto the FCEV, wherein the flexible energy storage sub system (106) further comprises a fuel cell cooling sub-system, one or more hydrogen cylinders (314), mounting brackets (312) for respective hydrogen cylinders, and balance of plant fuel cell (310), and wherein, using the interface (102), one or more battery packs (202) are replaceable by corresponding hydrogen cylinders (314) and/or fuel cell stacks (306) for FCEV conversion without any change in the architecture.

9. The system (100) as claimed in claim 10, wherein the one or more hydrogen cylinders (314) and the mounting brackets (312) for respective hydrogen cylinders form part of a hydrogen cylinder sub-system (304) that further comprises any or a combination of receptacle, hydrogen piping, sensor(s), safety protection device(s), wiring harness, and control system, said hydrogen cylinder sub-system (304) being further coupled with a mechanical interface (102-3) to enable use of hydrogen compatible piping and connectors to facilitate coupling between the fuel cell stack(s) (306) with the one or more hydrogen cylinders (314).

10. The system (100) as claimed in claim 1, wherein the interface (102) enables transition of energy mode of the flexible energy storage sub-system (106) from pure battery based mode to fuel-cell based mode, said interface (102) further enabling change in configuration of the flexible energy storage sub- system (106) through an electronic control unit (ECU) (406).