AE HEV New Model Course

2. High Voltage Battery

 Overview High Voltage Battery

▶ AE EV High-voltage Battery

 Kilometraje maximizado para carga única mediante la aplicación del sistema de baterías de alta salida /
alta capacidad. → 98 kW / 28 kWh (kilometraje para carga única : 191 km) Montado el sistema de baterías
en la parte inferior del vehículo → espacio interior y maletero asegurado que es igual a los vehículos
generales.
 Battery Pack
(at the bottom of the vehicle)
 BMU
(Battery Management
Unit)

PTC
Temperature
Elevation
Heater (battery module)

[HEV] [EV]
※ Battery temperature elevation
450 heater is optional.
Fuel Tank
Battery mm
(45 L)
Battery 1.56 kWh Multi-link Battery 28 kWh CTBA
 System Configuration High Voltage Battery

Composition of High-voltage Battery

Battery Module
(12 modules)
Cooling Fan • Cell voltage and temperature Battery Cell
• Optimal battery temperature control sensing (6/10 cells) • Save / Supply
energy

A -

BMU
+
• Battery control and failure diagnosis

Safety Plug
• Prevent overcurrent and
PRA cut off power during
• Supply / Block power and maintenance
measure current
 High Voltage Battery
System Configuration (High-voltage Circuit)

12 V Battery
Elevation Heater
Temperature

(12 units /
Charging

Optional)

Junction Block
Normal
Quick /

High-voltage
Port

Compressor
Electric
⑥

④
③
②
①

Reducer
OF F 요청 HV MA IN RE LAY (+) 고전 압 구동 부품
IG MCU
Ke y
HV MA IN RE LA Y( -) LDC
NO /OFF BMS
요청
ECU
Re la y 고전압 공조부 품
TC U HCU Driv e HV PRE CHA RGE R ELA Y

VCU/MCU
NO /OFF
AIR B AG 상태 FATC
OFF 요청 HV MAI NRE LA Y(+) 고전압 구동부품

Capacitor
GI MCU
Key
HV MAI NR ELAY( -)
LD C

－
NO / OFF BM S
청
요
ECU
eRl ay 고전압 공조부품
TCU
HCU Driv e HVPRECH ARGE RELA Y
NO / OFF
AIRBA G 태
상 FA TC
OFF 요청 HV MAI NRE LA Y (+) 고전압 구동부품
GI MCU
Key
HV MAI N RELAY (- )
LDC
ON OF/ F BM S
청
요
ECU
Rel ay 고전압 공조부품
TCU
HCU rDiv e HVPR EC HARGE RELA Y
ON OF/ F
AIRBA G 상태 FATC
OFF 요청 HV MAIN RELAY (+) 고전압 구동부품
GI MC U
Key
HV MAI NRE LA Y (- )
LD C

+
ON /OFF BM S
요청
ECU
Rela y 고전압 공조부품
TCU HCU rDiv e HV PRECH ARGE R ELAY
ON OF/ F
AIRBAG 태
상 FA TC
OFF 요
청 HV MAI N RELAY(+) 고전압 구동부품
GI MCU
Key
HV M AIN RELAY( -) LDC
ON/ OFF BM S
요청
EC U
HC U eR la y 고전압 공조부품
TCU Dri ve HV PRECHARG E RELAY
ON/ OFF
AIR BAG 상태 FATC

OBC
OF F 요청 HVMAIN RE LAY (+) 고전압 구동부 품
IG MCU
Ke y
HV MA INR EL AY (- ) LDC
NO /OFF BMS
요청
ECU
Re la y 고전압 공조부 품
TCU HC U Dr iv e HV PRE CHAR GE RE LA Y
NO /OFF
AIRB AG 상태 FA TC

⑫
⑪

Inverter
Safety Plug

Motor
PRA

EPCU
+ LDC
PTC
 Components High Voltage Battery

▶ High-voltage Junction Block

 Acts as a power distributor that connects high-voltage battery to PE components.

 It is mounted on the side of EPCU and has a busbar and fuse inside.
EPCU (Capacitor / Inverter)

EPCU
HV High-voltage
JB Battery
OBC

PTC Heater
High-voltage
Junction Block

Electric
OBC Compressor

 Fuse 40 A
OBC
30 A
Electric Compressor
40 A
PTC Heater
 Components High Voltage Battery

▶ Battery Pack

Safety Plug

Quick
Charging 7 modules 6 modules
_10 cells _10 cells
Busbar

10 cells 8 modules 5 modules

1 module _10 cells _10 cells

9 modules 4 modules
_10 cells _10 cells

10 modules 3 modules
_6 cells _6 cells

6 cells 11 modules 2 modules

1 module _6 cells _6 cells

12 modules 1 module
_6 cells _6 cells

+ －

PRA
Components High Voltage Battery

▶ BMU, CMU

 BMU (Battery Management Unit) : Controls the overall battery pack and communicates with other
controllers inside the vehicle.
 CMU (Cell Monitoring Unit) : Manages cell balancing and module temperature.

BMU (1 CMU (10 units)

EA)

Mounted inside the bottom

cover of the PRA
Components High Voltage Battery

▶ PRA

 Function : Main relay for supplying or blocking the high-voltage battery power to or from PE components.
 Configuration : Main relay +, -, precharge relay, quick charging relay, temperature elevation heater relay

PRA

Bus bar

Precharge Resistance

Quick Charging Relay

Main Relay (+,-)

PRA Lower Cover Removed

 Components High Voltage Battery

▶ PRA Circuit

 PRA Control : BMU receives a CAN signal from VCU to control PRA.

Precharge Relay

Main Relay

Quick
Quick Charging
Relay + － Charging Port

Temperature
Elevation Heater
Relay

High-voltage
Junction Block
EPCU
Components High Voltage Battery

▶ Safety Plug

 Removable plug location : Trunk compartment

 When the safety plug is removed, a circuit inside the high-voltage battery is disconnected.

7 modules 6 modules
_10 cells _10 cells

8 modules 5 modules
_10 cells _10 cells

9 modules 4 modules
Safety Plug _10 cells _10 cells
(250 A fuse embedded)
10 modules 3 modules
_6 cells _6 cells
Interlock Circuit
11 modules 2 modules
_6 cells _6 cells

12 modules 1 module
_6 cells _6 cells
+ －

PRA
Battery Control System High Voltage Battery

▶ BMU

Battery Module (CMU) Battery Pack (PRA)

Measur
ement Cell Cell Current
Voltage Temp.

Main Functions
of BMU
Key On/Off
① SOC Estimation Information
SOC Management
② Relay Control
Battery CAN
Communication
Control ③ Cooling Control SOC
Unit

Fan Speed Relay

Control Control

Drive Unit Cooling Fan PRA

 Battery Control System High Voltage Battery

▶ Cooling System

 Uses a cooling fan to generate air flow inside the battery case and cool the high-voltage battery.
 Operates a cooling fan according to the vehicle speed (when the air temperature inside the battery
pack is 31℃ or above).

High-voltage Battery Cooling Fan

 Battery Control System High Voltage Battery

attery Temperature Elevation System (Optional)

 Battery temperature rises at low-temperature charging condition

→ Reduces charging time in extremely cold weather.
 A PTC heater is mounted on the side of battery module (Each of the 12 modules has a PTC heater)

7 modules 6 modules
_10 cells _10 cells

PTC
8 modules 5 modules
Temperature _10 cells _10 cells
Elevation Heater
(Battery Module)
9 modules 4 modules
_10 cells _10 cells

10 modules 3 modules
_6 cells _6 cells

11 modules 2 modules
_6 cells _6 cells

12 modules 1 module
_6 cells _6 cells

+ －

PRA
Battery Control System High Voltage Battery

▶ OPD _ Overvoltage Protection Device

 Applied a switch to detect expansion of the high-voltage battery due to overcharging.

 A total of 12 switches and 1 relay(including the internal switch) are mounted on each module of the
high-voltage battery (mounted on the top and rear of the module).
 1 OPD relay

6 switches

Mounted on the rear of the

battery pack
 A total of 12 OPD switches

6 switches

The switch is pressed when

the battery cell expands.
 Battery Control System High Voltage Battery

▶ OPD Circuit Configuration

 If any of the 12 switches (NC type) is open, the ground line of PRA main relay (+, -) coil is
automatically disconnected. → PRA Off
 If the internal switch (NO type) of OPD relay is closed, the OPD relay is open. → PRA Off

• OPD relay : NC
PRA  Switch : Normal Close • Switch : NO
EPCU
OFF 요청 HV MAIN RELAY(+) 고전압 구동부품 OFF 요청 HV MAIN RELAY(+) 고전압 구동부품

IG MCU IG MCU

+
Key Key

HV MAIN RELAY(-) HV MAIN RELAY(-)

LDC LDC
ON/OFF BMS ON/OFF BMS
요청 요청
ECU ECU
Relay 고전압 공조부품 Relay 고전압 공조부품
TCU HCU Drive HV PRECHARGE RELAY TCU HCU Drive HV PRECHARGE RELAY
ON/OFF ON/OFF
AIRBAG 상태 FATC AIRBAG 상태 FATC

－
OFF 요청 HV MAIN RELAY(+) 고전압 구동부품

IG MCU
Key

HV MAIN RELAY(-)
LDC
ON/OFF BMS
요청
ECU
Relay 고전압 공조부품
TCU
HCU Drive HV PRECHARGE RELAY
ON/OFF
AIRBAG 상태 FATC

BMU Main
Relay

IG3 Power >

 Battery Control System High Voltage Battery

▶ Securing the safety of battery system

1st
Cooperation of • Prevent the occurrence of safety issues through cooperative control with vehicle
vehicle controller
controllers.

2nd • Monitor battery voltage, current, and temperature in real time.

Active protection • Use the battery optimally with SOC calculation and cell balancing functions.
(BMU control)
• Applied a high-voltage cut-off relay(PRA).

• Applied a service plug to cut off the high current (fuse) and secure safety for
3rd
maintenance.
Manual
protection • In the case of overcharging
- Applied a structure that cuts off the current when battery deformation.
- Applied a structure that cuts off the current through OPD

4th • Applied a ceramic-coated separator (to improve mechanical and

Battery
thermal stability).
Cell
• Applied a LIPB battery that generates little heat.
• Applied a pouch battery that has excellent heat dissipation capability.
 System Diagnosis High Voltage Battery

▶ High-voltage Interlock Circuit

 Each controller monitors the interlock to check the connection of the high-voltage cable.
 The controller detects the voltage change. The interlock is engaged when the high-voltage connector is
engaged and disengaged when the connector is disengaged.
① Safety Plug ② PRA-side ③ High-voltage ④, ⑤ High-voltage Junction Block → PTC
Connection Cable Junction Block Heater

⑥ Electric Compressor
System Diagnosis High Voltage Battery

▶ Isolation Breakdown Detection Function

 Perform the insulation test on major components that use high voltage.
 Perform diagnosis after forming a high-voltage closed circuit between the battery and each controller.
 Perform insulation test by applying voltage using the high-voltage battery (360 V)
(similar to a mega ohm meter).
System Diagnosis High Voltage Battery

▶ Actuation Test List

 Operate the PRA main relay and

precharge relay.

 Operate the quick charging relay.

 Operate the temperature elevation heater

relay.