High-efficiency and high-adaptability series formation system

Abstract

The invention provides a high-efficiency and high-adaptability series formation system, which comprises a high-energy-efficiency power cabinet module and a high-energy-efficiency needle bed module, the high-energy-efficiency power cabinet module and the high-energy-efficiency needle bed module are connected through n groups of positive and negative electrode output lines, and the high-energy-efficiency power cabinet module comprises a high-voltage energy feedback module and an adaptability matching module, the adaptive matching module is electrically connected with the high-voltage energy feedback module through a signal line, and a series formation system charging framework is flexibly selected through a control signal; the high-energy-efficiency needle bed module comprises a battery state processing module and a battery pack module, the battery pack module comprises a plurality of batteries and a plurality of short-circuit wires, and the battery pack module is formed by connecting the plurality of batteries in the high-energy-efficiency needle bed module through the plurality of short-circuit wires. According to the high-efficiency and high-adaptability series formation system, the efficiency of the formation stage can be optimized, and the flexibility of equipment remodeling can be improved.

Description

Technical Field

[0001] The invention relates to the technical field of battery processing, and in particular to a highly efficient and highly adaptable series formation system. Background Art

[0002] In the prior art, a necessary stage in the production of single cells is "formation", that is, after the single cells are assembled, they are charged and discharged under certain conditions to activate the active substances on the electrodes of the single cells, and at the same time, a dense film is generated on the surface of the anode to protect the entire chemical interface.

[0003] There are many charging solutions for the battery formation stage on the market, among which the most common solutions are parallel or series solutions. The main advantage of the parallel solution is that when one of the batteries has a problem, it will not affect the normal charging and discharging of other channels, while the traditional battery direct series solution will cause the entire string to stop working, and the charging flexibility is weak. However, the cost and line loss of the parallel solution are higher, and each battery requires a separate energy feedback module to support it, while the series solution only needs one energy feedback module for a string of batteries, with a simple structure and fewer lines. In terms of efficiency, the series solution is better than the parallel solution.

[0004] In addition, the emergence of CC bypass series connection and CV bypass series connection makes up for the flexibility of traditional direct series connection of batteries in charging. These two solutions are collectively referred to as bypass series connection. Compared with the direct series connection of batteries, the efficiency of this solution will be reduced due to the length of the wire connecting the newly added battery to the bypass box outside the needle bed.

[0005] Nowadays, the series connection scheme is generally used for medium voltage solutions, and it is difficult to further improve the system efficiency. At the same time, if the market wants to change to a different series connection scheme, it is necessary to change the equipment in large quantities, and the equipment has poor adaptability and is difficult to change.

[0006] Therefore, it is necessary to provide a series formation system with high efficiency and adaptability to optimize the efficiency of the formation stage and improve the flexibility of equipment conversion. Summary of the invention

[0007] In view of the deficiencies of the prior art, the present invention proposes a highly efficient and highly adaptable series formation system, which can optimize the efficiency of the formation stage and improve the flexibility of equipment conversion.

[0008] To realize the above technical scheme, the present invention provides a high-efficiency and highly adaptable series formation system, including: a high-efficiency power supply cabinet module and a high-efficiency needle bed module, the high-efficiency power supply cabinet module and the high-efficiency needle bed module are connected through n groups of positive and negative output lines, the high-efficiency power supply cabinet includes a high-voltage energy feedback module and an adaptive matching module, the adaptive matching module is electrically connected to the high-voltage energy feedback module through a signal line, and the charging architecture of the series formation system is flexibly selected through a control signal; the high-efficiency needle bed module includes a battery status processing module and a battery pack module, the battery pack module includes a plurality of batteries and a plurality of short-circuit wires, and the battery pack module is formed by a plurality of batteries connected inside the high-efficiency needle bed module through the plurality of short-circuit wires.

[0009] Preferably, the high-voltage energy feedback module includes an ACDC module and an isolated DCDC module. The ACDC module serves as the input end of the high-voltage energy feedback module to provide a high-voltage 700V DC bus for the isolated DCDC module. The high-voltage 700V DC bus serves as the DC input source of the isolated DCDC module. The isolated DCDC module serves as the output end of the high-voltage energy feedback module. Both ends of the isolated DCDC module are electrically connected to the battery pack module respectively, and the ACDC module is electrically connected to the isolated DCDC module.

[0010] Preferably, the high-voltage energy feedback module is internally composed of a plurality of isolated DCDC modules connected in series.

[0011] Preferably, the DCDC module adopts a phase-shifted full-bridge current-doubler rectification scheme.

[0012] Preferably, the battery status processing module is used to collect the voltage of each battery cell in real time and transmit it to the high-voltage energy feedback module through the CAN line. If the voltage of a battery cell reaches a set value, the battery status processing module will bypass the battery cell, maintain a constant voltage for a single cell, or stop charging and discharging the entire string according to the selected series formation system charging architecture.

[0013] Preferably, the control signal in the adaptive matching module is a software configuration or a hardware configuration, the software configuration is a software code that directly configures the selected system charging architecture, and the hardware configuration is to select different system charging architectures in the form of a dial code.

[0014] Preferably, the system charging architecture includes a battery direct series charging architecture and a bypass series charging architecture, and the bypass series charging architecture includes a CC bypass series charging architecture and a CV bypass series charging architecture. If the control signal is configured in the form of a dial code, the dial code selection 0001 represents the battery direct series charging architecture, the dial code selection 0010 represents the CC bypass series charging architecture, and the dial code selection 0011 represents the CV bypass series charging architecture.

[0015] Preferably, in the battery direct series charging architecture, the battery status processing module includes a monitoring module, which is used to perform voltage sampling on several batteries in the battery pack module in real time and upload data to the high-voltage energy feedback module through CAN communication in a timely manner, and one end of the battery pack module is directly connected to one end of the high-voltage energy feedback module, and the other end of the battery pack module is directly connected to the other end of the high-voltage energy feedback module. The several batteries are connected in series through the several short-circuit wires. If a battery in the battery pack module reaches the set voltage upper limit, the high-voltage energy feedback module will stop current output.

[0016] Preferably, in a series charging architecture with bypass, the battery status processing module includes a plurality of switching units, which form a plurality of battery switching modules, the plurality of switching units are independently provided with a monitoring unit, and one end of the high-voltage energy feedback module is connected to one end of a certain battery switching module, and the other end of the high-voltage energy feedback module is connected to the other end of a certain battery switching module, the plurality of switching units in the battery switching module string form a series relationship through PCB routing, the plurality of batteries are connected to the plurality of switching units through the plurality of short-circuit wires, the switching unit samples the voltage data of the connected batteries in real time and uploads it to the high-voltage energy feedback module through CAN communication, if a battery in the battery pack module reaches the set voltage upper limit, the switching unit will execute the cut-out or single-cell constant voltage working condition, and will not affect the normal operation of the total current output by the high-voltage energy feedback module.

[0017] Preferably, the connection of the battery direct series charging architecture and the battery pack series charging architecture with bypass series charging architecture are both completed inside the needle bed.

[0018] The beneficial effects of the highly efficient and adaptable tandem formation system provided by the present invention are:

[0019] (1) The present invention can flexibly select the series formation system charging architecture through the adaptive matching module through the control signal. The series formation system charging architecture includes a battery direct series charging architecture and a bypass series charging architecture, and the bypass series charging architecture is a charging architecture with a cut-in, cut-out function and a single-channel constant voltage charging function.

[0020] (2) The high-efficiency needle bed module of the present invention is connected in series inside the needle bed, overcoming the disadvantage of the existing external series connection in terms of line length. The existing external series connection method is to pull the power line of the needle bed probe module out of the needle bed, and then use a short-circuit wire from the outside to connect them in series, resulting in large line losses in the entire series. Each short-circuit wire in the internal series connection is made of a copper strip or soft copper wire, which is only the length of the probe module spacing, thereby minimizing system line losses and increasing efficiency.

[0021] (3) The present invention improves the output voltage level by connecting the plurality of isolated DCDC modules in series, making the system more adaptable and compatible with more battery series charging and discharging environments.

[0022] (4) The present invention adopts a high-voltage 700V DC bus, which can further improve efficiency compared to the existing medium-voltage DC bus. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 It is the overall framework of the highly efficient and highly adaptable series formation system in the present invention.

[0024] Figure 2 It is a detailed diagram of the highly efficient and highly adaptable series formation system of the present invention.

[0025] Figure 3 It is a system diagram of the direct series charging architecture of the high-efficiency and highly adaptable series formation system in the present invention.

[0026] Figure 4 This is a system diagram of a highly efficient and adaptable series formation system with a bypass series charging architecture in the present invention.

[0027] Figure 5 It is a formation system diagram of a plurality of isolated DCDC modules connected in series in the present invention.

[0028] Figure 6 This is a diagram of the traditional direct series needle bed wiring method.

[0029] Figure 7 This is a diagram of the traditional needle bed wiring method with bypass series connection.

[0030] Figure 8 It is a needle bed wiring diagram of the direct series charging architecture of the high-efficiency and high-adaptability series formation system in the present invention.

[0031] Fig. 9 It is a needle bed wiring diagram of a highly efficient and adaptable series formation system with a bypass series charging architecture in the present invention. DETAILED DESCRIPTION

[0032] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. All other embodiments obtained by ordinary persons in the art without creative work are within the scope of protection of the present invention.

[0033] Embodiments of the present invention are now described with reference to the accompanying drawings, in which similar element numbers represent similar elements. It should be noted that the orientation descriptions involved in the present invention, such as the orientations or positional relationships indicated by up, down, left, right, front, and back, are all based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the technical solutions or / and simplifying the descriptions of the present application, rather than indicating or implying that the devices or elements referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as limitations on the present application. The first, second, etc. described are only used to distinguish technical features, and cannot be understood as indicating or implying relative importance or implicitly indicating the number of the indicated technical features or implicitly indicating the order of the indicated technical features. The described quantitative nouns 1, 2, n, m, etc. are only used for simplified descriptions of quantity and cannot be understood as limitations on the quantitative descriptions of the present application.

[0034] Embodiment: A highly efficient and adaptable tandem formation system.

[0035] First combine Figure 1 , Figure 2 As shown, the high-efficiency and highly adaptable series formation system provided by the present invention includes a high-efficiency power supply cabinet module 100 and a high-efficiency needle bed module 200. Among them, there are n groups of positive and negative output lines electrically connected between the high-efficiency power supply cabinet module 100 and the high-efficiency needle bed module 200. Among them, the high-efficiency power supply cabinet 100 includes a high-voltage energy feedback module 110 and an adaptive matching module 120. The high-efficiency needle bed module 200 includes a battery status processing module 210 and a battery pack module 220. The battery pack module 220 includes a plurality of batteries 222 and a plurality of short-circuit wires 221. The battery pack module 220 is formed by connecting the plurality of batteries 222 inside the high-efficiency needle bed module 200 through the plurality of short-circuit wires 221.

[0036] In the present invention, the high-voltage energy feedback module 110 includes an ACDC module 111 and an isolated DCDC module 112. The ACDC module 111 serves as the input end of the high-voltage energy feedback module 110 and provides a high-voltage 700V DC bus for the isolated DCDC module 112. The high-voltage 700V DC bus serves as the DC input source of the isolated DCDC module 112. The isolated DCDC module 112 serves as the output end of the high-voltage energy feedback module 110, and its two ends are electrically connected to the high-efficiency needle bed module 200 respectively. The ACDC module 111 is electrically connected to the isolated DCDC module 112.

[0037] In one embodiment of the present invention, the isolated DCDC module 112 uses a high-voltage 700V DC bus, which upgrades the existing medium-voltage (80-150V) input platform to a high-voltage 700V input platform. While the output power remains unchanged, the diameter of the input cable can be effectively reduced, thereby reducing costs and increasing system efficiency.

[0038] More specifically, the conventional series formation system adopts a medium voltage input solution, and the DCDC module of the medium voltage input solution adopts a non-isolated BUCK-BOOST solution, which is not only inefficient, but also has no electrical isolation between input and output, and the output stability cannot be guaranteed. In addition, due to the stress of components, the non-isolated BUCK-BOOST cannot be applied to high-voltage input platforms. In the high-voltage 700V DC bus input solution described in the present invention, the isolated DCDC module 112 adopts a phase-shifted full-bridge current doubler rectification solution to reduce the stress of power devices under the high-voltage 700V DC bus and reduce device costs. And the input and output ends of the isolated DCDC module 112 use transformers for electrical isolation to reduce coupling interference between input and output.

[0039] More specifically, under the high-voltage 700V bus input platform, the traditional DCDC module often uses 650V silicon MOS, and proposes a three-level or multi-channel series solution, which is relatively complex to control and has poor reliability. The present invention uses a 1200V silicon carbide MOS with a higher withstand voltage, and the proposed phase-shifted full-bridge current doubler rectification solution makes the circuit topology more streamlined. At the same time, compared with silicon-based devices, the third-generation conductor silicon carbide can work in harsh environments such as high temperature, high voltage, and interference, which improves conversion efficiency while greatly improving reliability.

[0040] See below Figure 3 , Figure 4 As shown, in one embodiment of the present invention, the adaptive matching module 120 is electrically connected to the high-voltage energy feedback module 110 through a signal line, and can flexibly select the series connection to form a system charging architecture through a control signal according to on-site requirements. The control signal can be a software configuration or a hardware configuration, either of the two. The software configuration is a software code that directly configures the selected system charging architecture; the hardware configuration is to select different system charging architectures in the form of a dial code.

[0041] More specifically, the series formation system charging architecture includes a battery direct series charging architecture and a bypass series charging architecture, and the bypass series charging architecture includes a CC bypass series charging architecture and a CV bypass series charging architecture. If the control signal is configured in the form of a dial code, the dial code selection 0001 indicates a battery direct series charging architecture; the dial code selection 0010 indicates a CC bypass series charging architecture; and the dial code selection 0011 indicates a CV bypass series charging architecture.

[0042] More specifically, in the battery direct series charging architecture, the battery state processing module 210 includes a monitoring module 212, and the monitoring module 212 can sample the voltage of several battery cells 222 in the battery pack module 220 in real time and upload the data to the isolated DCDC module 112 in the high-voltage energy feedback module 110 in time through CAN communication. In this series charging architecture, the battery pack module 220 may have m battery groups in series, and the high-voltage energy feedback module 110 may also have m output channels. One end of the mth battery group 223 is directly connected to one end of the mth output channel of the high-voltage energy feedback module, and the other end of the mth battery group is directly connected to the other end of the mth output channel of the high-voltage energy feedback module. The several battery cells 222 are connected in series through the several short-circuit wires 221. If a battery cell in the battery pack module 220 reaches the set voltage upper limit, the high-voltage energy feedback module 110 will stop the current output.

[0043] More specifically, in the bypass series charging architecture, the battery state processing module 210 includes a plurality of switching units 213. The plurality of switching units 213 form the plurality of battery switching modules 211. The plurality of switching units 213 independently have a monitoring unit 214. The battery pack module 220 may have m battery packs, and the battery state processing module 210 may also have m battery switching modules. In the bypass series charging architecture, one end of the high-voltage energy feedback module 110 is connected to one end of the m-th battery switching module 211, and the other end of the high-voltage energy feedback module 110 is connected to the other end of the m-th battery switching module 211. The plurality of switching units 213 in the m-th battery switching module 211 form a series relationship through PCB routing. The n-th battery 222 is connected to the n-th switching unit 213 through the n-th short-circuit 221. The n-th switching unit 213 can sample the voltage data of the connected battery in real time and upload it to the high-voltage energy feedback module 110 through CAN communication. If a battery in the battery pack module 220 reaches the set voltage upper limit, the switching unit 213 will execute the cut-out or single-cell constant voltage operation without affecting the normal operation of the total current output by the high-voltage energy feedback module 110.

[0044] See below Figure 5 As shown, in one embodiment of the present invention, in order to adapt to the high-voltage environment of more battery cells connected in series, the present invention increases the output voltage level of the system by connecting a plurality of the isolated DCDC modules 112 in series.

[0045] More specifically, the cathode of the first isolated DCDC module 112 is electrically connected to the anode of the second isolated DCDC module 112, and the cathode of the second isolated DCDC module 112 is electrically connected to the anode of the third isolated DCDC module 112; similarly, the cathode of the (n-1)th isolated DCDC module 112 is electrically connected to the anode of the nth isolated DCDC module 112. Then, the anode of the first isolated DCDC module 112 is electrically connected to the anode input terminal of the high-efficiency needle bed module, and the cathode of the nth isolated DCDC module 112 is electrically connected to the cathode input terminal of the high-efficiency needle bed module.

[0046] See below Figure 6 and Figure 8 , Figure 7 and Fig. 9 As shown, in one embodiment of the present invention, the wiring of the battery direct series charging architecture and the battery pack series charging architecture with bypass series charging architecture are both completed inside the needle bed, without pulling the cable of the probe module to the outside of the needle bed for wiring.

[0047] More specifically, see again Figure 6 and Figure 8 , through the adaptive matching module, the charging architecture of the system can be selected as a direct series charging architecture. Figure 6 That is, it is a traditional direct series needle bed wiring method. Under this wiring method, the input and output cables of the several batteries 222 in the needle bed 300 need to be connected to the external terminal block 400 outside the needle bed, and then several short-circuit wires 224 are used on the external terminal block to connect each channel in series. Figure 8 As shown, this is the efficient and highly adaptable direct series connection method for the needle bed of the present invention. In this connection method, the plurality of batteries 222 are directly connected in series inside the needle bed 300 through a plurality of short-circuit wires 224, and the circuit is simple, beautiful and short.

[0048] More specifically, see again Figure 7 and Fig. 9 Through the adaptive matching module, the charging architecture of the system can be selected as a charging architecture with bypass series connection. Figure 7 That is, it is a traditional needle bed wiring method with bypass series connection. Under this wiring method, the input and output cables of the several batteries 222 in the needle bed 300 need to be connected to the bypass box 500 outside the needle bed, and then the channels are connected in series through PCB routing in the external bypass box 500. Figure 8As shown, the present invention is a highly efficient and adaptable needle bed wiring method with bypass series connection. In this wiring method, the plurality of batteries 222 are connected to the plurality of switching units 213 in the needle bed interior 300 through a plurality of short-circuit wires 224, and the plurality of switching units are connected in series through short-circuit wires. The circuit is also much simpler, more beautiful and shorter than the traditional solution.

[0049] In summary, the highly efficient and adaptable tandem formation system of the present invention has the following technical effects:

[0050] (1) The present invention adopts a high-voltage 700V DC bus, which can further improve efficiency compared to the existing medium-voltage DC bus.

[0051] (2) The present invention can flexibly select the series formation system charging architecture through the adaptive matching module through the control signal. The series formation system charging architecture includes a battery direct series charging architecture and a bypass series charging architecture. The bypass series charging architecture is a charging architecture with a cut-in, cut-out function and a single-channel constant voltage charging function.

[0052] (3) The present invention improves the output voltage level by connecting the plurality of isolated DCDC modules in series, making the system more adaptable and compatible with more battery series charging and discharging environments.

[0053] (4) The high-efficiency needle bed module overcomes the disadvantage of the existing external series line length by connecting in series inside the needle bed. The existing external series connection method is to pull the power line of the needle bed probe module out of the needle bed, and then use a short-circuit wire from the outside to connect in series, resulting in large line losses in the entire series. Each short-circuit wire in the internal series connection is made of copper strips or soft copper wires, which is only the length of the probe module spacing, thereby minimizing system line losses and increasing efficiency.

[0054] The above description is only a preferred embodiment of the present invention, but the present invention should not be limited to the contents disclosed in the embodiment and the drawings, so any equivalent or modification completed without departing from the spirit disclosed in the present invention shall fall within the scope of protection of the present invention.

Claims

1. A highly efficient and adaptable tandem formation system, characterized in that include: A high-efficiency power supply cabinet module and a high-efficiency needle bed module, wherein the high-efficiency power supply cabinet module and the high-efficiency needle bed module are connected via n groups of positive and negative output lines, the high-efficiency power supply cabinet comprises a high-voltage energy feedback module and an adaptive matching module, the adaptive matching module is electrically connected to the high-voltage energy feedback module via a signal line, and a series formation system charging architecture is flexibly selected via a control signal; the high-efficiency needle bed module comprises a battery status processing module and a battery pack module, the battery pack module comprises a plurality of batteries and a plurality of short-circuit wires, and the battery pack module is formed by a plurality of batteries connected inside the high-efficiency needle bed module via the plurality of short-circuit wires.

2. A highly efficient and adaptable tandem formation system as claimed in claim 1, characterized in that: The high-voltage energy feedback module includes an ACDC module and an isolated DCDC module. The ACDC module serves as the input end of the high-voltage energy feedback module and provides a high-voltage 700V DC bus for the isolated DCDC module. The high-voltage 700V DC bus serves as the DC input source of the isolated DCDC module. The isolated DCDC module serves as the output end of the high-voltage energy feedback module. Both ends of the isolated DCDC module are electrically connected to the battery pack module respectively, and the ACDC module is electrically connected to the isolated DCDC module.

3. A highly efficient and adaptable tandem formation system as claimed in claim 1, characterized in that: The high-voltage energy feedback module is internally composed of a plurality of isolated DCDC modules connected in series.

4. A highly efficient and adaptable tandem formation system as claimed in claim 1, characterized in that: The DCDC module adopts a phase-shifted full-bridge current-doubler rectification scheme.

5. The high-efficiency and highly adaptable tandem formation system according to claim 1, characterized in that: The battery status processing module is used to collect the voltage of each battery in real time and transmit it to the high-voltage energy feedback module through the CAN line. If the voltage of a battery reaches a set value, the battery status processing module will bypass the battery, keep a single battery constant voltage, or stop charging and discharging the entire string according to the selected series formation system charging architecture.

6. The high-efficiency and highly adaptable tandem formation system according to claim 1, characterized in that: The control signal in the adaptive matching module is a software configuration or a hardware configuration. The software configuration is a software code that directly configures the selected system charging architecture, and the hardware configuration is to select different system charging architectures in the form of a dial code.

7. A highly efficient and adaptable tandem formation system as claimed in claim 6, characterized in that: The system charging architecture includes a battery direct series charging architecture and a bypass series charging architecture. The bypass series charging architecture includes a CC bypass series charging architecture and a CV bypass series charging architecture. If the control signal is configured in the form of a dial code, the dial code selection 0001 represents the battery direct series charging architecture, the dial code selection 0010 represents the CC bypass series charging architecture, and the dial code selection 0011 represents the CV bypass series charging architecture.

8. A highly efficient and adaptable tandem formation system as claimed in claim 7, characterized in that: In the battery direct series charging architecture, the battery status processing module includes a monitoring module, which is used to sample the voltage of several batteries in the battery pack module in real time and upload data to the high-voltage energy feedback module through CAN communication in a timely manner. One end of the battery pack module is directly connected to one end of the high-voltage energy feedback module, and the other end of the battery pack module is directly connected to the other end of the high-voltage energy feedback module. The several batteries are connected in series through the several short-circuit wires. If a battery in the battery pack module reaches the set voltage upper limit, the high-voltage energy feedback module will stop current output.

9. A highly efficient and adaptable tandem formation system as claimed in claim 8, characterized in that: In the bypass series charging architecture, the battery status processing module includes a plurality of switching units, which form a plurality of battery switching modules, the plurality of switching units are independently provided with a monitoring unit, and one end of the high-voltage energy feedback module is connected to one end of the battery switching module of a certain string, and the other end of the high-voltage energy feedback module is connected to the other end of the battery switching module of a certain string, the plurality of switching units in the battery switching module of the string form a series relationship through PCB routing, the plurality of batteries are connected to the plurality of switching units through the plurality of short-circuit wires, the switching unit samples the voltage data of the connected batteries in real time and uploads it to the high-voltage energy feedback module through CAN communication, if a battery in the battery pack module reaches the set voltage upper limit, the switching unit will execute the cut-out or single-cell constant voltage working condition, and will not affect the normal operation of the total current output by the high-voltage energy feedback module.

10. A highly efficient and adaptable tandem formation system as claimed in claim 9, characterized in that: The connection of the battery direct series charging architecture and the battery pack series charging architecture with bypass series charging architecture are both completed inside the needle bed.

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