Bi-directional Battery Balancing Circuit for Mining EV Modules
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Solution Overview
Problem
Heavy-duty electric vehicle batteries in mining operations face inefficiencies and overheating due to uneven charge distribution among battery cells, leading to reduced performance and shorter lifespan, as weaker cells leak charge faster and operate under varying temperatures.
Innovation Solution
A battery management system with bi-directional balancing circuits and power supply that balances individual battery cells within modules by distributing excess charge from stronger cells to weaker ones, ensuring all cells reach a similar charge level, thereby optimizing power efficiency and extending module life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If battery cells operate under varying temperatures and rough conditions, then the battery system can function in heavy duty mining applications, but the battery cells weaken at different rates and develop uneven charge distribution
Solution Approach 1:
The patent implements individual balancing circuits for each battery cell or small groups of cells, allowing localized charge adjustment. This enables each cell to be balanced independently according to its specific charge state, addressing the uneven degradation caused by varying operating conditions while maintaining overall system adaptability.
Solution Approach 2:
The battery system is divided into multiple battery modules, with each module containing multiple battery cells that can be balanced independently. This segmentation allows the system to handle varying conditions in different parts of the battery pack separately, preventing charge distribution issues from propagating throughout the entire system.
2Reliability
If battery balancing systems are implemented to equalize cell charges, then battery efficiency and lifespan are improved, but the system complexity increases
Solution Approach 1:
The patent combines multiple balancing circuits into integrated modules that can handle multiple cells simultaneously. The balancing system is merged with the existing battery module structure, sharing common components such as control logic and power management infrastructure, thereby reducing overall system complexity while maintaining effective cell-level balancing.
Solution Approach 2:
The balancing circuits are designed with multi-functional capabilities, serving both as charging balancers and as diagnostic monitoring systems. This universal design reduces the need for separate dedicated balancing hardware, simplifying the overall system architecture while improving reliability through enhanced monitoring and control.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system enhances power efficiency, extends the operating cycle of battery modules, and minimizes downtime by evenly balancing cell charges, allowing for more precise monitoring and maintenance of battery health.
Implementation Method 1
The first converter is configured to increase or decrease the voltage between the first battery cell and a bus bar
Data Source
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AI summary
The disclosed battery management system generally includes at least one bi-directional balancing circuit and a power supply including a first battery module and a second battery module, each having at least one battery cell. The balancing circuit may be configured to transfer excess charge from one or more battery cells of the first battery module to one or more battery cells of the second battery module. By redistributing the level of charge within one or more battery cells, the balancing circuit can cause the overall charge of a power supply to last longer by taking advantage of excess charge found within one or more battery cells. Additionally, the balancing circuit may be connected to a bus bar that may be utilized to power additional accessories within a vehicle.