Battery Cell Matching Across Capacity, Voltage, and Resistance
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Solution Overview
Problem
Current techniques fail to effectively match cells across multiple characteristics during battery assembly, leading to inefficiencies and increased leftover cells, as cell characteristics are often uncorrelated, making it difficult to ensure compatibility across all parameters.
Innovation Solution
A multi-characteristic cell matching process that evaluates cells based on multiple parameters such as capacity, open circuit voltage, resistance, and self-discharge rate, using a cell compatibility matrix and sorting cells by their compatibility scores to identify optimal cell combinations for battery assembly, while incorporating tiebreaker techniques to handle tied compatibility values.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If single-characteristic cell matching techniques are used, then the matching process is simple, but cells cannot be matched across multiple characteristics leading to increased leftover cells
Solution Approach 1:
The patent transforms the cell matching problem from single-parameter to multi-parameter evaluation by calculating compatibility scores across multiple characteristics (capacity, voltage, resistance, self-discharge rate). This allows comprehensive matching that reduces leftover cells while maintaining computational feasibility through systematic score aggregation.
Solution Approach 2:
The patent creates a composite compatibility score that integrates multiple cell characteristics into a single evaluation metric. By combining capacity, voltage, resistance, and self-discharge rate into one composite score, the system achieves multi-characteristic matching without overwhelming complexity.
2Reliability
If multi-characteristic cell matching is implemented, then cell compatibility is improved, but the complexity of the matching process increases
Solution Approach 1:
The patent divides the multi-characteristic matching problem into separate evaluation components, each handling a specific characteristic (capacity, voltage, resistance, self-discharge rate). By segmenting the evaluation into distinct scoring functions that are later aggregated, the system manages complexity while maintaining comprehensive compatibility assessment.
Solution Approach 2:
The patent transforms multiple independent characteristics into a unified compatibility score through mathematical aggregation. This parameter transformation converts the complex multi-dimensional matching problem into a simpler single-score comparison, reducing process complexity while preserving reliability.
3Manufacturing precision
If cells are matched based on uncorrelated characteristics independently, then each characteristic can be optimized, but overall cell compatibility across all characteristics deteriorates
Solution Approach 1:
The patent creates a composite compatibility evaluation that integrates multiple uncorrelated characteristics into a unified assessment. By combining capacity, voltage, resistance, and self-discharge rate scores into one composite compatibility metric, the system ensures overall cell compatibility while maintaining the ability to evaluate each characteristic independently.
Solution Approach 2:
The patent merges multiple independent characteristic evaluations into a single comprehensive compatibility score. By combining the results of separate characteristic assessments through weighted aggregation, the system achieves both individual characteristic optimization and overall compatibility assurance.
Data Source
AI summary
For each cell in a plurality of cells from a same manufacturing run, a first and a second cell characteristic are received in order to obtain a plurality of cell characteristics. For each cell, a batch compatibility number that is associated with a number of compatible cells that that cell is compatible with is determined based at least in part on the plurality of cell characteristics. The plurality of cells is sorted according to the batch compatibility numbers to obtain a sorted list of cells. A plurality of compatible cells to include in a battery is selected from the plurality of cells, including by evaluating the plurality of cells according to the order of the sorted list of cells and beginning with the lowest batch compatibility number.