An optimizer for adjusting battery module power

Abstract

The utility model relates to an optimizer for adjusting battery module power, include: front end plug connector socket, rear end plug connector plug, bypass relay, power board, the connector socket is used for connecting system output end, and the connector plug is used for connecting battery module, and the positive pole end of power board connection plug and socket is connected through the conductive row, and the bypass passageway is provided between the positive pole end of bypass relay, and the optimizer switches between straight -through mode and power regulation mode according to the electric quantity difference, the utility model solves the technical problem that the capacity loss and the connection structure maintenance complex are caused by the inconsistent electric quantity of series connection battery module.

Description

Technical Field

[0001] This invention relates to an optimizer for adjusting the power of a battery module. Background Technology

[0002] In applications such as energy storage systems, multiple battery modules are often connected in series to meet the requirements of high voltage levels and long-term operation. However, in battery systems with multiple modules connected in series, due to factors such as manufacturing errors, aging, and uneven temperature, inconsistencies in the state of charge (i.e., state of charge) can easily occur between different modules during charging and discharging.

[0003] When there are differences in charge levels among series-connected battery modules, the module that reaches its voltage or capacity limit first during charging and discharging becomes the bottleneck, preventing the entire system from being fully charged or discharged, resulting in capacity loss, known as the "endplate effect." To address this issue, existing technologies typically employ equalization control strategies, commonly including passive and active equalization.

[0004] Passive balancing releases excess energy through resistor dissipation, which is simple in structure but inefficient and introduces significant heat loss in high-current applications. Active balancing uses inductors, capacitors or converters to transfer excess energy to other modules, which has a higher energy utilization rate, but is complex to control, costly, and has a large circuit structure with low integration.

[0005] In addition, traditional battery module connection structures mostly use fixed cable connections, which are cumbersome to operate during maintenance, replacement or expansion, and are prone to problems such as poor contact and poor safety, making it difficult to meet the needs of high-density deployment and rapid maintenance.

[0006] Therefore, there is an urgent need for an optimizer device that is compact, has efficient heat dissipation, automatic power regulation capability, and a highly reliable connection method, in order to dynamically adjust the power state of the battery module, improve system capacity utilization, reduce circuit energy consumption, and simplify system maintenance and installation procedures. Utility Model Content

[0007] The purpose of this invention is to address the shortcomings of the prior art and provide an optimizer for adjusting the power of a battery module.

[0008] An optimizer for adjusting the power of a battery module includes: a front-end connector socket, a rear-end connector plug, a bypass relay, and a power board. The front-end connector socket is used to connect to the system output terminal, and the rear-end connector plug is used to connect to the battery module. The input terminal of the power board is connected to the positive terminal of the plug connector, and the output terminal is connected to the positive terminal of the plug connector socket. The negative terminal of the plug connector and the negative terminal of the plug connector socket are connected through a conductive connector bar. The bypass relay is used to provide a bypass path between the positive terminal of the plug connector and the positive terminal of the plug connector socket. The optimizer is adapted to the control system and switches between the following two operating modes based on the detected differences in battery module charge levels: Straight-through mode: The bypass relay is turned on, the power board does not participate in power regulation, and the current is directly output from the positive terminal of the plug to the positive terminal of the socket. Power regulation mode: When the bypass relay is disconnected, the power board is engaged to achieve power regulation of the battery module.

[0009] Furthermore, the power board is mounted on a tray, the power semiconductor devices on the power board are disposed on the side facing down from the tray, a heat sink is provided under the tray, and thermal grease is filled between the power board and the heat sink.

[0010] Furthermore, a fan is provided on one side of the heat sink to dissipate the heat generated by the power semiconductor device during the operation of the optimizer.

[0011] Furthermore, an inductor is provided below the power board, and the power board, inductor, heat sink and fan constitute an integrated power component structure.

[0012] Furthermore, the optimizer has a housing, and the power component is disposed in the central region of the housing.

[0013] Furthermore, the rear plug connector is located at the tail of the optimizer, and the bottom of the optimizer is provided with a guide groove, which is used to cooperate with the guide block on the support structure to achieve limiting docking.

[0014] Furthermore, the control system is configured to automatically determine whether to switch to power regulation mode based on the power difference between multiple battery modules, and switch back to direct transmission mode after power balance is achieved.

[0015] Beneficial effects: Compared with the prior art, this utility model provides an optimizer for adjusting the power of a battery module. By introducing a working mode switching mechanism based on dynamic judgment of power differences and a structured electrical connection scheme, it realizes adaptive power adjustment and system consistency control of the battery module in series applications, and has the following advantages: Improve battery module balancing efficiency This invention utilizes a bypass relay and a power board to construct a dual-path structure. When the system detects a difference in charge between modules, it can control the switching to power regulation mode, actively intervene in the current flow of the modules, achieve fast and accurate capacity balancing, significantly improve the charging and discharging consistency of the entire system, and avoid the capacity waste problem caused by the "endboard effect".

[0016] Reduce system energy consumption and circuit losses When the difference in module power is small, the optimizer automatically runs in pass-through mode, the power board does not participate in circuit transmission, and the current is directly transmitted through the bypass path, which effectively reduces energy loss and device heating, and extends the system life.

[0017] High structural integration and excellent heat dissipation. This invention integrates a power board, heat sink, inductor, and fan into a single power component. The MOS device and the custom heat sink are in full contact through thermal grease. Combined with a forced air cooling structure, this improves thermal management efficiency and ensures system stability and safety under high power conditions.

[0018] Modular blind-mating design improves connection efficiency and reliability. The optimizer is equipped with a blind-mating connector plug at the tail end and a guide groove at the bottom. It works with the guide block on the bracket to achieve automatic positioning and limit docking, eliminating the need for manual plugging and unplugging operations. This significantly simplifies the maintenance and replacement process and is suitable for rapid operation and maintenance needs in high-density deployment scenarios.

[0019] Improve system compatibility and scalability Through standardized electrical interface and plug-in structure design, the optimizer of this invention can be widely adapted to various battery module systems, facilitating future expansion or batch replacement, and enhancing the system's flexibility and long-term adaptability.

[0020] Intelligent control strategy, high system operating efficiency The optimizer's control system can dynamically determine whether to intervene and adjust based on the power status of multiple modules, and can automatically restore the direct-flow mode after reaching equilibrium. It has a high degree of automation and intelligence, which helps to improve the operating efficiency and management convenience of the entire system. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the overall structure of the optimizer; Figure 2 yes Figure 1 The main view; Figure 3 This is a schematic diagram of the power component structure; In the diagram, 1 is the front-end connector socket, 2 is the bypass relay, 3 is the rear-end connector plug, 4 is the tray, 5 is the fan, 6 is the power board, and 7 is the heat sink. Detailed Implementation

[0022] To enhance understanding of this utility model, the present utility model will be further described in detail below with reference to the embodiments and accompanying drawings. These embodiments are only used to explain the present utility model and do not constitute a limitation on the scope of protection of the present utility model.

[0023] An optimizer for adjusting the power of a battery module includes: a front-end connector socket 1, a rear-end connector plug 3, a bypass relay 2, and a power board 6. The front-end connector socket 1 is used to connect to the system output, and the rear-end connector plug 3 is used to connect to the battery module. The input terminal of the power board 6 is connected to the positive terminal of the connector plug, and the output terminal is connected to the positive terminal of the connector socket. The negative terminals of the connector plug and the connector socket are connected via a conductive connector bar. The bypass relay 2 provides a bypass path between the positive terminals of the connector plug and the connector socket. This optimizer is adapted to a control system and switches between a direct-flow mode and a power regulation mode based on the detected battery module charge difference: In direct-flow mode, the bypass relay 2 is on, the power board 6 does not participate in power regulation, and the current is directly output from the positive terminal of the connector plug to the positive terminal of the connector socket; in power regulation mode, the bypass relay 2 is off, the power board 6 intervenes, and the battery module power is regulated.

[0024] The optimizer achieves reliable connection with the battery modules and system output through a plug-in connector structure. Power board 6 is positioned in the positive path. When the control system detects a charge difference between the battery modules, it disconnects the bypass relay 2, allowing power board 6 to operate and regulate the power output, thereby balancing the charge states between the battery modules. When the charge levels are similar or the system determines that no adjustment is needed, the control system drives bypass relay 2 to switch to direct-flow mode. Current is directly output from the battery modules to the system, and power board 6 does not participate in operation, thus reducing energy consumption and improving system efficiency.

[0025] This implementation integrates the bypass relay 2 and the power board 6, resulting in a simple and efficient structure that allows for flexible switching between two operating modes. When there is uneven charge levels in the battery modules, it can automatically intervene to adjust the system, improving overall battery system performance and lifespan. Conversely, when the charge levels are equal, it can switch to direct transmission, reducing unnecessary energy consumption and heat generation, thus improving system reliability and economy. Furthermore, the modular structure of this solution facilitates maintenance and system integration.

[0026] In one possible implementation, the power board 6 is mounted on the tray 4, the power semiconductor devices on the power board 6 are disposed on the side facing down from the tray 4, a heat sink 7 is provided under the tray 4, and thermal grease is filled between the power board 6 and the heat sink 7.

[0027] This embodiment fixes the power board 6 to the tray 4 structure, using the tray 4 as a mechanical support and heat conduction platform. The power semiconductor device is positioned below the tray 4, allowing its heat to be directly conducted downwards to the heat sink 7. Thermal grease is filled between the power board 6 and the heat sink 7, effectively reducing the thermal resistance between them, improving heat conduction efficiency, and ensuring the thermal stability of the power semiconductor device during long-term operation.

[0028] This design, through its compact layout, improves the heat dissipation performance of power devices, extends device lifespan, and reduces heat loss. Simultaneously, this structure facilitates modular design, benefiting overall assembly and maintenance. The application of thermal grease enhances thermal coupling, ensuring heat dissipation under high power loads.

[0029] In one possible implementation, a fan 5 is provided on one side of the heat sink 7 to dissipate the heat generated by the power semiconductor device during the operation of the optimizer.

[0030] This design adds a fan 5 assembly to one side of the heat sink 7, allowing the heat absorbed by the heat sink 7 to be quickly expelled through air convection. The fan 5 creates forced airflow, effectively removing the large amount of heat generated by the power semiconductor device during operation, maintaining a stable device surface temperature, and preventing performance fluctuations or damage caused by temperature rise.

[0031] This implementation significantly improves heat dissipation efficiency, enhances system stability and continuous operating capability, and is particularly suitable for applications with large power fluctuations or prolonged high loads. At the same time, the air-cooled system has a simple structure, is easy to maintain, and offers good cost-effectiveness.

[0032] In one possible implementation, an inductor is provided below the power board 6, and the power board 6, inductor, heat sink 7 and fan 5 constitute an integrated power component structure.

[0033] This structure integrates the power board 6 with the inductor, heat sink 7, and fan 5 into a single module. Optimized layout reduces the resistance and inductance of internal connection paths, while also facilitating unified allocation by the thermal management system. The inductor is positioned below the power board 6, reducing electromagnetic interference and maximizing space utilization. This integrated structure enhances the module's internal compactness and collaborative operating efficiency.

[0034] The highly integrated structure simplifies the overall layout and assembly process, improves product consistency and stability, and reduces the overall size, which is beneficial for achieving high-performance optimization within a limited space. Furthermore, the modular design facilitates future maintenance, replacement, and system upgrades.

[0035] In one possible implementation, the optimizer has a housing, and the power component is disposed in the central region of the housing.

[0036] The optimizer's overall structure features a robust protective enclosure to isolate it from external environmental influences. Placing the integrated power components in the central area of ​​the enclosure facilitates even heat distribution and symmetrical airflow paths, while also improving the stress balance of the mechanical structure and system stability. This central placement also simplifies internal wiring management and space planning.

[0037] This design enhances the system's structural strength and anti-interference capabilities, effectively preventing the influence of external factors such as dust and moisture on the circuitry. Simultaneously, it optimizes heat dissipation channels and electromagnetic compatibility, improving the long-term reliability of the equipment.

[0038] In one possible implementation, the rear plug connector plug 3 is located at the tail of the optimizer, and the bottom of the optimizer is provided with a guide groove, which is used to cooperate with the guide block on the support structure to achieve limiting docking.

[0039] A plug-in connector at the tail of the optimizer enables convenient docking with the battery module. A guide groove structure at the bottom of the optimizer, mating with guide blocks on the external support structure, restricts the relative position during insertion, ensuring precise alignment of the plug and battery module. This limiting function prevents misalignment or damage during connection, improving insertion efficiency and stability.

[0040] This structure simplifies the optimizer installation process, improves the accuracy and safety of mechanical connections, and reduces manual alignment errors, making it particularly suitable for automated assembly scenarios. Simultaneously, the guide structure offers excellent repeatability, improving the efficiency of system maintenance and replacement.

[0041] In one possible implementation, the control system is configured to automatically determine whether to switch to power regulation mode based on the power difference between multiple battery modules, and switch back to direct transmission mode after power balance is achieved.

[0042] This control system determines the charge status of multiple connected battery modules by detecting parameters such as voltage and current. When the system detects a significant charge difference between the battery modules, it automatically disconnects bypass relay 2, switching to power regulation mode to achieve power balance. Once the charge difference is eliminated or a set threshold is reached, the control system reconnects bypass relay 2, restoring the direct-flow mode and improving overall efficiency.

[0043] This implementation method achieves intelligent balancing management among battery modules without manual intervention, effectively extending battery life and improving the overall performance of the vehicle or energy storage system. The automated control logic enhances the system's intelligence and operational efficiency, adapting to complex and ever-changing application scenarios.

[0044] The above description is only a preferred embodiment of the present utility model and is not intended to limit the present utility model. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.

Claims

1. An optimizer for adjusting the power of a battery module, comprising: A front-end plug-in connector socket, a rear-end plug-in connector plug, a bypass relay, and a power board are characterized in that the front-end plug-in connector socket is used to connect to the system output terminal, and the rear-end plug-in connector plug is used to connect to the battery module. The input terminal of the power board is connected to the positive terminal of the plug connector, and the output terminal is connected to the positive terminal of the plug connector socket. The negative terminal of the plug connector and the negative terminal of the plug connector socket are connected through a conductive connector bar. The bypass relay is used to provide a bypass path between the positive terminal of the plug connector and the positive terminal of the plug connector socket. The optimizer is adapted to the control system and switches between the following two operating modes based on the detected differences in battery module charge levels: Straight-through mode: The bypass relay is turned on, the power board does not participate in power regulation, and the current is directly output from the positive terminal of the plug to the positive terminal of the socket. Power regulation mode: When the bypass relay is disconnected, the power board is engaged to achieve power regulation of the battery module.

2. The optimizer for adjusting the power of a battery module according to claim 1, characterized in that, The power board is mounted on a tray, and the power semiconductor devices on the power board are located on the side facing down from the tray. A heat sink is located under the tray, and thermal grease is used to fill the space between the power board and the heat sink.

3. The optimizer for adjusting the power of a battery module according to claim 2, characterized in that, A fan is provided on one side of the heat sink to dissipate the heat generated by the power semiconductor device during the operation of the optimizer.

4. The optimizer for adjusting the power of a battery module according to claim 3, characterized in that, An inductor is located below the power board, and the power board, inductor, heat sink, and fan constitute an integrated power component structure.

5. The optimizer for adjusting the power of a battery module according to claim 4, characterized in that, The optimizer has a housing, and the power component is located in the central region of the housing.

6. The optimizer for adjusting the power of a battery module according to claim 1, characterized in that, The rear plug connector is located at the tail of the optimizer. The bottom of the optimizer is provided with a guide groove, which is used to cooperate with the guide block on the support structure to achieve limit docking.

7. The optimizer for adjusting the power of a battery module according to claim 1, characterized in that, The control system is configured to automatically determine whether to switch to power adjustment mode based on the power difference between multiple battery modules, and switch back to direct transmission mode after power balance is achieved.

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