Mercedes micro-converter: revolution in battery management

High-voltage architecture Micro-converter technology transforms battery management

2024-12-04 From Dipl.-Ing. (FH) Michael Richter | Translated by AI 2 min Reading Time

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Mercedes aims to provide the powertrain with a constant output voltage through micro-converters, regardless of the charge level, cell chemistry, or age of a cell.

Highly integrated battery for Mercedes' MMA platform. The research department is working on novel battery management techniques, employing micro-converters.(Image: Mercedes-Benz AG) — Highly integrated battery for Mercedes' MMA platform. The research department is working on novel battery management techniques, employing micro-converters.
(Image: Mercedes-Benz AG)

Mercedes-Benz provided deep insights into developments in the field of power electronics during the technology workshop "Mercedes Future Experience". A programmable micro-converter is intended to regulate the voltage directly at the level of individual battery cells.

For this approach, micro-converters are integrated at the cell level, allowing each individual battery cell to be controlled and charged individually. The micro-converters enable direct communication between the cells, allowing the charging and discharging processes to be controlled. Conventional battery management systems regulate the cells in series-connected groups. In contrast, the new system allows each cell to be considered as an independent unit, achieving a more flexible and efficient energy management.

Constant voltage regardless of charge state

With this technology, a constant output voltage of 800 volts can be provided. This is independent of the state of charge (SoC), cell chemistry, or the age of the battery cells (State of Health, SoH). This is achieved through the parallel connection of the cells in combination with the power converter, which consists of a multitude of micro-converters. Previously, the output voltage depended on the number of series-connected cells. Instead, the number of cells here is defined only by the desired power and capacity class.

According to Mercedes, the constant output voltage increases the efficiency of the electric powertrain. It no longer needs to be designed for a wide voltage range as before. Electric motors have ideal operating points where they work most efficiently, as these depend on torque, current, and voltage.

Claire Magne is the global product manager at TE Connectivity. (Image:Benjamin Schenk)

Isolate individual cells if defective

The micro-converter also enables faster charging and reduces energy losses during charging. Besides these advantages, controlling individual cells improves battery lifespan. Typically, individual defective cells are responsible for the failure of a module. These cells can be isolated or selectively replaced without affecting the entire system.

Mercedes-Benz aims to increase the efficiency of electric vehicles. However, whether this approach will be incorporated into new models in the near future or if other manufacturers will develop similar concepts remains to be seen. (mr)

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