Battery Cell Matching for Performance Consistency
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Large-scale batteries composed of modular sub-units of commercial off-the-shelf battery cells face performance variability due to differences in individual cell and component performance, which affects overall battery efficiency and reliability.
Innovation Solution
A method and system that determine a design layout for batteries by matching operational parameters of battery cells and electrical components, selecting combinations that meet predetermined thresholds, and providing indications for potential combinations to ensure consistent performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If modular sub-units of commercial off-the-shelf battery cells are used to construct large-scale batteries, then the battery can be assembled with flexible layout and using readily available components, but performance variability occurs due to differences in individual cell and component performance
Solution Approach 1:
The patent applies preliminary action by measuring and characterizing individual battery cells and electrical components before assembly, creating a database of their operational parameters. This pre-screening process identifies cells and components with matching characteristics, allowing them to be pre-grouped into balanced sets that will perform consistently when assembled into modular battery units. This preliminary matching prevents performance variability issues from arising during operation.
Solution Approach 2:
The patent applies local quality by recognizing that different battery cells and components have unique operational characteristics (voltage, capacity, internal resistance, temperature coefficients) and treating each individual cell/component as having its own specific quality profile. Rather than assuming uniformity across all components, the system measures and matches each component's local characteristics to ensure compatibility within specific modular assemblies, thereby achieving consistent overall battery performance.
2Ease of manufacture
If individual battery cells and components are manufactured with standard tolerances, then manufacturing cost is reduced and ease of manufacture is improved, but performance variability increases affecting overall battery efficiency
Solution Approach 1:
The patent applies parameter changes by measuring actual operational parameters (voltage, capacity, internal resistance, temperature coefficients) of each battery cell and electrical component, then using these measured parameters to match and group components. This transforms the approach from relying on nominal manufacturer specifications to using actual measured parameters, thereby compensating for standard manufacturing tolerances and achieving consistent battery performance without requiring tighter manufacturing tolerances.
Solution Approach 2:
The patent applies feedback by measuring the operational parameters of individual cells and components, comparing these measurements against desired performance criteria, and using this information to select and group compatible components together. This feedback loop ensures that only components with matching characteristics are assembled into the same modular battery unit, maintaining high efficiency while allowing standard manufacturing tolerances.
Data Source
Figure 1
Figure 2
Figure 3A
AI summary
A method, system (102), and a computer readable medium enables determining a design layout (400) of a battery (602) that includes an electrical arrangement of one or more battery cells (110) and one or more electrical components (112). The method also includes determining operational parameters of a batch of battery cells (110) and electrical components (112) to potentially be used in the battery (602) and selecting at least one battery cell (110) and at least one electrical component (112) for the electrical arrangement of the design layout (400). The method further includes comparing the operational parameters of the at least one battery cell (110) and at least one electrical component (112) and determining that the operational parameters of the at least one battery cell (110) and at least one electrical component (112) are within a predetermined threshold. The method includes selecting the at least one battery cell (110) and at least one electrical component (112) as a potential combination for the design.